Systems, apparatuses, and methods of substance processing

ABSTRACT

A substance processing system includes a pressurizer configured to pressurize air and a processing chamber configured to process a substance. The system also includes a heat exchanger coupled between the pressurizer and the processing chamber. A nozzle is coupled to the processing chamber such that output from the nozzle comprises a substantially even pressure distribution.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority benefit, under 35 U.S.C. § 119(e), toU.S. provisional application Ser. No. 62/682,675, filed Jun. 8, 2018,and entitled “SYSTEMS, APPARATUSES, AND METHODS OF SUBSTANCEPROCESSING”, which is hereby incorporated herein by reference in itsentirety.

BACKGROUND

Every year more than 3.5 billion pounds of unroasted coffee beans areimported into the U.S. to be roasted and consumed by 60% of the U.S.population. Over a million businesses in the U.S. serve coffee each yearbut only a few thousand businesses are able to roast their own coffeegiven inherent complexities to the process and operating existingequipment. Roasting coffee on-site (i.e., roasting the coffee where thecoffee beverages are prepared and served) can improve the coffeefreshness, reduce the inventory loss rates due to shelf life (unroastedcoffee beans usually have a much longer shelf life), and increaseprofitability.

Currently, roasting of coffee beans is typically carried out atcentralized locations due to the space, cost, and expertise required.Existing coffee roasting equipment is typically large and expensive,requiring manual operation by skilled “roast masters.” The roast mastercontrols variables in coffee roasting, including but not limited toairflow through the roasting drum, tumbling speed of the roasting drum,and heat application to name a few variables. The roast master manuallymanipulates these variables in real-time on the equipment to control the“roast profile” of the coffee beans. However, these variables and theresulting roast profile are usually unknown to other people, includingpurchasers and retailers. As a result, only a limited number of peoplehave access to the equipment and the roasting expertise.

Moreover, coffee is freshest within 10-14 days after roasting, whichapplies downward pressure on the coffee supply chain. In contrast, theshelf life of unroasted coffee is typically on the order of about 1 yearfrom the time of milling processing at origin. Manufacturers currentlyuse various gases and other means to preserve roasted whole bean andground coffee, which is packaged to improve the shelf life afterroasting. However, this processing can impact the taste and quality ofthe end product.

“Third wave” specialty coffee producers may address the desire for freshcoffee of consumers by using high quality coffee beans and reducing thetime between roasting and sale. Over the last five years, “third wave”specialty coffee producers have raised significant capital and investedin brick and mortar infrastructure, including high cost roastingequipment. They also hire personnel with the required expertise tosource and roast specialty coffee, taking the first steps towardsdecentralizing coffee roasting from large plants. However, thesebusinesses normally are only able to cater to retailers within a certaingeographic radius of their infrastructure. As an example, Blue BottleCoffee, which is perhaps the most recognized third wave coffee supplierin the U.S., announced in 2016 that it was exiting its wholesalebusiness due to issues with cost, quality, and supply chain.

Unroasted coffee is roughly one-seventh the price of roasted coffeewhether it be for first, second, or third-wave coffees. By way ofexample, third wave coffee roasters typically pay $3-$4 per pound forgreen unroasted coffee beans and then sell for $21 to $28 per pound atretail. Coffee retailers sourcing wholesale third-wave coffee forserving or selling pay an average of $10-$14 for roasted specialtycoffee beans. There is significant inefficiency in the coffee market andsupply chain, as well as limited profitability for coffee retailers dueto all of the above factors.

SUMMARY

Embodiments disclosed herein include apparatus, systems, and methods forsubstance processing. In some embodiments, an apparatus includes areceptacle configured to receive a container containing a substance forprocessing. The container includes a readable tag having processinginformation associated with the substance. The apparatus also includes aprocessing chamber operably coupled to the receptacle and configured toreceive the substance and process the substance. The apparatus furtherincludes a controller operably coupled to the processing chamber andconfigured to generate one or more processing instructions based on theprocessing information in the readable tag and further based onadditional processing information received from a remote device. Theprocessing is also configured to process the substance based on the oneor more processing instructions.

In some embodiments, a method includes receiving a container containinga substance for processing. The container includes a readable tag havingprocessing information associated with the substance. The method alsoincludes generating processing instructions, using a controller, basedat least in part on the processing information read from the readabletag and additional processing information received from a remote deviceor contained locally on the substance processor. The method alsoincludes dispensing the substance in the container into a processingchamber and processing the substance based at least in part on theprocessing instructions.

In some embodiments, a system includes a plurality of roasting devicesand each roasting device includes a receptacle configured to receive acontainer. The container includes a substance for processing and thecontainer further includes a tag having processing information. Eachroasting device also includes a tag reader configured to read theprocessing information from the tag on the container and a processingchamber to process the substance. The system also includes a computingdevice, which includes a memory configured to store a plurality ofroasting instructions. Each roasting instruction of the plurality ofroasting instructions has corresponding processing informationassociated therewith. The computing device also includes a communicationinterface operably coupled to the memory and a processor operablycoupled to the memory and the communication interface. The processor isconfigured to execute executable instructions to receive the processinginformation via the communication interface from at least one roastingdevice, retrieve the roasting instruction corresponding to theprocessing information from the memory, and control the communicationinterface to transmit that roasting instruction to the at least oneroasting device.

In some embodiments, an apparatus associated with a master coffeeroaster configured for roasting a sample of a green coffee andgenerating a plurality of roasting instructions, the plurality ofroasting instructions usable by a plurality of user coffee roasters isdisclosed. The apparatus includes memory to store a plurality ofroasting instructions and each roasting instruction in the plurality ofroasting instructions has corresponding identification information. Theapparatus also includes a communication interface operably coupled tothe memory and a processor operably coupled to the memory and thecommunication interface. The processor being configured to executeexecutable instructions to receive the identification information viathe communication interface from at least one user coffee roaster,retrieve the roasting instruction corresponding to the identificationinformation from the memory, and control the communication interface totransmit the roasting instruction to the at least one user roastersending the identification information.

BRIEF DESCRIPTIONS OF DRAWINGS

FIG. 1 illustrates a schematic of a platform for on-site substanceprocessing, according to embodiments.

FIG. 2 illustrates a method of integrated coffee roasting, according toembodiments.

FIG. 3 illustrates a schematic of a system for integrated coffeeroasting according to embodiments.

FIG. 4 illustrates a schematic of a platform for users to roast coffee,according to embodiments.

FIGS. 5A and 5B are example interfaces for facilitating on-site coffeeroasting, according to embodiments.

FIG. 6 illustrates a method of substance processing, according toembodiments.

FIG. 7 illustrates a block diagram of a distributed system for substanceprocessing, according to embodiments.

FIGS. 8A-8D illustrate various views a compact coffee roaster, accordingto embodiments.

FIGS. 9A and 9B illustrate two cooling trays that can be used in theroaster shown in FIGS. 8A-8D, according to embodiments.

FIGS. 10A and 10B illustrate a coffee roasting system including amechanism to open consumables within a roaster, according toembodiments.

FIGS. 11A-11C illustrate an opener design useful for openingconsumables, according to embodiments.

FIGS. 12A-12D illustrate a trash bag opener used for openingconsumables, according to other embodiments.

FIGS. 13A-13D illustrate a consumable opener, according to otherembodiments.

FIG. 14A illustrates a perspective view of a compact roaster, accordingto embodiments.

FIG. 14B illustrates another perspective view of the compact roasterdepicted in FIG. 14A.

FIG. 15A illustrates a perspective view of a roasting chamber andnozzle, according to embodiments. FIG. 15B is a cross-sectional view ofthe nozzle depicted in FIG. 15A. FIG. 15C is a schematic cross-sectionalview of the nozzle depicted in FIG. 15A.

FIG. 16 illustrates a plot of flow rate and pressure drop of a roaster,according to embodiments.

FIG. 17 illustrates a block diagram of a roaster system, according toembodiments.

FIGS. 18A-18G illustrate methods of opening a consumable, according toembodiments.

DETAILED DESCRIPTION

Systems, apparatus, and methods described herein are directed to anintegrated substance processing platform for a user to process asubstance on-site. For example, the platform can be used for on-sitecoffee roasting. In such instances, the user can include a business(e.g., a coffee shop, a grocery store), an individual customer who makescoffee at home, or anyone who is interested in roasting coffee.

FIG. 1 illustrates a platform 100 (sometimes also referred to as anetwork, an environment, or a system) for users to perform on-sitesubstance processing. The platform 100 includes a processing apparatus110, a consumable 120 (also sometimes referred to as a container 120)containing a substance to be processed, and a database 130 (alsosometimes referred to as a server 130, including a server thatencompasses or is associated with the database 130). In some instances,a user associated with the processing apparatus 110 operates theprocessing apparatus 110 to process the substances contained in theconsumable 120, while another entity (sometimes also referred to as aservice party), such as a wholesale distributor, provides the consumable120 and maintains the database 130. The consumable 120 contains at leastone unprocessed or partially processed substance and includes a tag 125having processing information associated with that substance. Theprocessing apparatus 110 includes a receptacle 140 to receive theconsumable 120, a processing chamber 112 (also sometimes referred to asa substance processor) to process the substances, a controller 114 tocontrol the operation of the processing apparatus 110, and an optionaltag reader 115 to read the tag 125 included in the consumable 120.

In operation, and as described in greater detail herein, the user placesthe consumable 120 into the receptacle 140 of the processing apparatus110. The tag reader 115 reads the tag 125 (e.g., via scanning, imaging,or other suitable techniques for acquiring information from the tag) andtransmits the information in the tag 125 to the controller 114. Thecontroller 114 then generates specific instructions to direct theprocessor 112 to process the substances in the consumable 120 based onthe information contained in the tag 125 and also based on additionalprocessing information received from the database 130. The specificinstructions can be acquired directly or indirectly from the database130, as described in more detail herein. Since the specific instructionscan be provided by the third party and encoded through tag 125 on theconsumable 120 which is ready for immediate use, the user can processthe substance without developing any expertise about substanceprocessing, thereby allowing a wide range of people to perform on-sitesubstance processing.

In embodiments where the substance is unroasted green coffee beans(sometimes also referred to simply as “green coffee”), the processingchamber 112 in the processing apparatus 110 can be or include a roastingchamber; accordingly, the processing apparatus 110 is sometimes alsoreferred to as a roasting system 110. In such embodiments, theprocessing chamber 112 can be configured to roast the substance viaconductive heat application. In some embodiments, the processing chamber112 can be configured to roast the substance via convective heatapplication. In some embodiments, the processing chamber 112 can beconfigured to roast the substance via a combination of conductive heatapplication and convective heat application. In some embodiments, theprocessing chamber 112 is configured to roast the substance viainductive heat application. In some embodiments, the processing chamber112 can be configured to roast the substance via a combination of any ofthe above heating mechanisms.

In some embodiments, the receptacle 140 is configured to hold and securethe consumable 120 when the consumable 120 is placed into thereceptacle. In some embodiments, the consumable 120 has a weight(including the substance therein) of about 5 lbs or less (e.g., about 5lbs, about 4 lbs, about 3 lbs, or less, including any values and subranges in between). In some embodiments, the processing chamber 112 issized and configured to process about 15 lbs or less of the substance(e.g., about 15 lbs, about 10 lbs, about 9 lbs, about 8 lbs, about 7lbs, about 6 lbs, about 5 lbs, about 4 lbs, about 3 lbs, about 2 lbs,about 1.5 lbs, about 1 lbs, about 0.75 labs, or less, including anyvalues and sub ranges in between) at a given time. In this manner, theprocessing system and/or apparatus can be configured for “small batch”operation, and optimized for tabletop use.

In some embodiments, the receptacle 140 is configured to deliver thesubstance from the consumable 120 directly into the processing chamber112. For example, the consumable 120 can be opened by an opener and thesubstance can move into the processing chamber 112 under gravity force.More details about openers are provided below. (***in the example thatfollows, the hopper effectively replaces the receptacle. There's twoassociated versions between the hopper and the processing chamber. 1)without an airlock and 2) with an airlock.***)

In some embodiments, the processing apparatus 110 further includes ahopper (e.g., a funnel-shaped storage bin) to receive the substance inthe consumable 120 and then deliver the substance to the processingchamber 120 (e.g., before processing or during processing). In someembodiments, the processing apparatus 110 includes a valve disposedbetween the hopper and the processing chamber 112. In some embodiments,the valve can be controlled manually. In some embodiments, the valve canbe controlled by the controller 114. In some embodiments, the valve canbe configured to open (i.e. allowing the substance to pass through)before processing and close (i.e., blocking feeding of substance intothe processing chamber 112) during processing.

In some embodiments, the processing apparatus 110 further includes aholding chamber (not shown and sometimes referred to as an airlock) toreceive the substance in the consumable 120 from the receptacle 140, andthen to deliver the substance to the processing chamber 120. In someembodiments, the processing apparatus 110 includes a valve disposedbetween the holding chamber and the processing chamber 112. In someembodiments, the valve can be controlled manually. In some embodiments,the valve can be controlled by the controller 114. In some embodiments,the valve can be configured to open (i.e. allowing the substance to passthrough) before processing and close (i.e., blocking feeding ofsubstance into the processing chamber 112) during processing.

In some embodiments, the processing apparatus 110 includes a hopper toreceive the substance from the container 120 and an intermediate chamberto receive the substance from the hopper. The intermediate chamber thendelivers the substance into the processing chamber 112 when appropriate(e.g., before processing or during processing). In these embodiments, afirst valve can be disposed between the hopper and the intermediatechamber and a second valve can be disposed between the intermediatechamber and the processing chamber 112. In some embodiments, the hopperis in direct connection with the processing chamber 112 without theintermediate chamber.

The controller 114 in the processing apparatus 110 can include anysuitable type of controller configured as described herein. In someembodiments, the controller 114 is configured for wireless communicationwith the database 130, the tag reader 115, and/or the processing chamber112. The wireless communication can be achieved via, for example, WiFi,Bluetooth, long-term evolution (LTE) network, 4G network, 3G network,and/or the like. In some embodiments, the controller 114 is in wiredcommunication with the database 130, the tag reader 115, and theprocessing chamber 112. In some embodiments, the controller 114 has ahybrid communication capability. For example, the controller 114 cancommunicate with the database 130 via a wireless link, whilecommunicating with the tag reader 115 and the roaster 112 via a wiredlink.

In some embodiments, the controller 114 can be integrated with theprocessing chamber 112. In some embodiments, the controller 114 caninclude a micro-processor. In some embodiments, the controller 114 caninclude an embedded processor.

In some embodiments, the controller 114 can include or be part of aseparate device, such as a smartphone or tablet, to remotely control theprocessing chamber 112. In some embodiments, the controller 114 caninclude an internal controller integrated with the processing chamber112 and an external controller that is separate from the processingchamber 112. For example, the internal controller can include a simpleFPGA or an ASIC. The external controller can include a more powerfulprocessor and other components to wirelessly communicate with thedatabase 130 and/or to process the information provided by the tagreader 115.

In some embodiments, the tag reader 115 can be integrated with theprocessing chamber 112. For example, when the substance is green coffeebeans, the processing chamber/roaster 112 can receive and secure theconsumable/coffee pack 120 and then read the tag 125. After acquiringspecific instructions from the controller 114, the roaster 112 canautomatically open the coffee pack 120 and roast the coffee beans.

In some embodiments, the tag reader 115 can be a separate device (alsoreferred to as an external device) from the processing apparatus 110.For example, the tag reader 115 can include a portable barcode scanner,and the tag 125 can include a bar code. In some embodiments, the tagreader 115 can include a portable QR-code reader, and the tag 125 caninclude a QR code. In some embodiments, the tag reader 115 can include aportable Universal Product Code (UPC) reader, and the tag 125 includes aUPC code. In some embodiments, the tag reader 115 can include a portableradio frequency identification (RFID) reader, and the tag 125 includesan RFID tag. The tag reader 114 then transmits the scanned informationto the controller 114 via a wired or wireless link.

In some embodiments, the tag reader 115 and the controller 114 can beintegrated into a single device. For example, the tag reader 115 and thecontroller 114 can be integrated into a smartphone, which can read thetag 125 via a camera included in the smartphone. The controller 114 ofthe smartphone can also be configured to parse the read information,communicate with the database 130, and provide instructions to theroaster 112 to roast the coffee beans.

In some embodiments, the tag reader 115 can be integrated with thereceptacle 140. For example, when the consumable 120 is placed into thereceptacle 140, the tag reader 115 can then automatically read the tag125. In some embodiments, a sensor can be used to detect the presence(or the absence) of a consumable 120. Once a consumable 120 is detected,the controller 114 can then direct the tag reader 115 to read the tag125.

In some embodiments, the tag reader 115 is integrally formed with theprocessing apparatus 110 and is disposed outside the receptacle 140. Insome embodiments, a user can scan the consumable 120 using theintegrated tag reader 115 and then place the consumable 120 into thereceptacle 140. In some embodiments, a user can scan the consumable 120using the integrated tag reader 115 and then directly pour the substancein the consumable 120 into the processing chamber or a hopperoperatively connected to the processing chamber 112.

Explained hereon with respect to the embodiments where the substance isunroasted green coffee beans, various types of information can be readby the tag reader 115 from the tag 125. Said another way, various typesof information can be included (or encoded) into the tag 125. In someembodiments, the tag 125 can include roasting directions in a dataformat that can be directly implemented by the processingchamber/roaster 112. In such instances, the tag reader 115 can directlytransmit the instructions to the roaster 112. In such instances, thecontroller 114 may not consult with the database 130 for eachconsumable/coffee pack 120 received by the processing apparatus 110. Insome embodiments, the tag 125 includes roasting directions that can beparsed by the controller 114. After parsing, the controller 114 thentransmits the instructions to the roaster 112. Similarly, the controllermay not consult with the database 130 before sending the instructions tothe roaster 112.

In some embodiments, the tag 125 includes identification information (oraddress information) that can relate the coffee pack 120 to a particularset of instructions in the database 130. In some embodiments, theidentification information includes a serial number. The tag reader 115can acquire the serial number from the tag 125 and then consult with thedatabase 130 to retrieve the processing instructions corresponding tothis serial number. In some embodiments, the identification informationincludes an alphanumeric code, and the tag reader 115 can acquire thealphanumeric code from the tag 125 and then consult with the database130 to retrieve the processing instructions corresponding to thisalphanumeric code.

In some embodiments, the tag 125 includes additional information for theuser to modify and/or improve the roasting process and/or product (i.e.,roasted coffee beans). In some embodiments, the tag 125 includes theinformation about the type of the green coffee (e.g., varietal, origin,elevation, milling process, etc.) in the coffee pack 120. In someembodiments, the tag 125 includes the information about the origin ofthe green coffee (e.g., Brazil, Colombia, or Hawaii, etc.). In someembodiments, the tag 125 includes the expiration date of the greencoffee in the coffee pack 120. In some embodiments, the tag 125 includesthe age of the green coffee in the coffee pack 120. The expiration orthe age of the green coffee is information used by the controller togenerate and/or modify roasting instructions, including the scenariowhere the roasting instructions indicate that the green coffee shouldnot be roasted. For example, if the green coffee in a coffee pack 120has already expired (e.g., was packaged or otherwise originated prior toa predetermined date or time period), the controller can be configuredto stop the processing apparatus 110 from roasting the green coffee inthat coffee pack 120.

In some embodiments, the tag 125 includes processing information for thecontroller 114 to generate the processing instructions. For example, thetag 125 may include a desired or recommended roast level of the greencoffee. For example, the desired or recommended roast level can be lightroast, dark roast, or any other degree of roast. Upon receipt of thedesired or recommended roast level, the controller 114 then generatesthe processing instructions by adjusting the additional processinginformation (e.g., temperature profile) from the database 130.

The roasting instructions, either acquired from the tag 125 or retrievedfrom the database 130 based on information included in the tag 125,effectively includes a set of operation parameters for the roaster 112to roast the green coffee in the coffee pack 120. In some embodiments,the roasting instructions include a temperature over time curve T(t),where T is the roasting temperature and t is time.

The roasting process temperatures can be defined or characterized inseveral ways. In some embodiments, the roaster 112 can roast the coffeebeans via hot air and the roasting inlet temperature T_(g) can becharacterized as the temperature of the gas stream entering the roastingchamber (also referred to as the inlet temperature) in the roaster 112.The roasting temperature T_(b) can be characterized as the temperatureof the coffee beans in the roaster 112 during roasting. In suchinstances, the roasting temperature T can be acquired by, for example, atemperature probe in contact with the coffee. T_(c) can be characterizedas the temperature of the gas stream leaving (e.g. exhausting) theroasting chamber during roasting.

In some embodiments, the roaster 112 is configured to, based on theroasting instructions, automatically roast the green coffee withouthuman intervention. For example, the user can simply load the coffeepack 120 into the system 110, the tag reader 115 then automaticallyreads the tag 125, and the controller 114 can retrieve roastinginstructions from the database 130 and transmit the roastinginstructions to the roaster 112 to perform the roasting.

In some embodiments, the user can input some of the parameters based onthe roasting instructions. In some embodiments, in addition to theroasting instructions retrieved from the database 130, the user can alsoset a roasting preference, such as light roasts, medium roasts, mediumdark roasts, and dark roasts. In some embodiments, the user can updatethe roasting instructions based on the taste of the roasted coffee. Thisallows the platform 100 to accommodate different tastes of differentpeople, or to accommodate the same person's tastes at different times.

In some embodiments, the roasting instructions can include a set ofdefault instructions. During operation, the user can provide some otherparameters to modify the default instructions so as to derive the actualinstructions for the roaster 112. In some embodiments, the user canprovide environmental information such as the ambient temperature, thehumidity, or any other environmental parameters in the proximity of theroaster 112. The controller 114 can then update the roastinginstructions by taking into account this environmental information. Insome embodiments, the environmental information can be automaticallydetected and provided to the controller 114 by sensors included in theprocessing apparatus 110. In some embodiments, the environmentalinformation can be manually provided by the user.

In some embodiments, the roasting instructions can be displayed for theuser and then the user can manually input these instructions to theroaster 112. In this instance, the roaster 112 can operate manually.

As discussed herein, in some embodiments, the tag reader 115 can readthe tag 125 using radio frequency identification (RFID) techniques. Insuch instances, the tag 125 includes a RFID tag and the tag reader 115includes a RFID reader. The frequency used by the RFID technique can beabout 100 KHz to 10 GHz (e.g., about 100 KHz, about 200 KHz, about 300KHz, about 500 KHz, about 800 KHz, about 1 GHz, about 2 GHz, about 3GHz, about 5 GHz, about 8 GHz, or about 10 GHz, including any values andsub ranges in between).

In some embodiments, the tag reader 115 can read the tag 125 usingbarcode techniques. In some embodiments, the barcode includesone-dimensional (1D) barcode. In such instances, the 1D barcode can beread by a scanner and can include information such as a serial number ofthe pack 120 that includes the tag 125. In some embodiments, the barcodeincludes a two-dimensional (2D) barcode. In such instances, the 2Dbarcode can be directly read by a smartphone (e.g., via a smartphonecamera) and direct the smartphone to, for example, a webpage includingroasting instructions for the coffee beans contained in the coffee pack120. The controller 114 can then parse the webpage and acquire specificinstructions to control the roaster 112. In some embodiments, theprocessing apparatus 110 can include a 2D barcode reader as the tagreader 115 to read the tag 125.

In some embodiments, the tag reader 115 can read the tag 125 usingoptical pattern recognition techniques to read patterns included on thetag 125. In some embodiments, the optical pattern recognition techniquescan include the optical character recognition (OCR) technique. In someembodiments, the OCR reads characters on the tag 125. In someembodiments, the OCR reads numbers on the tag 125 and the numbers canform a serial number so as to allow the controller 114 to locate andretrieve from the database 130 the roasting instructions correspondingto this serial number.

In some embodiments, the tag 125 can include one or more magneticstripes and the tag reader 115 accordingly can include a magnetic stripereader. In some embodiments, the tag 125 can include a data storagedevice such as a memory chip. In some embodiments, the tag reader 115can read the tag 125 using any other automatic identification and datacapture (AIDC) techniques known in the art.

In some embodiments, it can be desirable to use the consumable/coffeepack 120 only once and avoid reuse. In such instances, the controller114 can be configured to store each processing information (e.g., aserial number) into a memory. Once another consumable 120 is placed intothe processing apparatus 110, the tag reader 115 reads the tag 125 andsends the processing information, including the serial number to thecontroller 114, which then checks the memory to determine whether thenewly detected serial number was detected before. If the controller 114determines that the latest serial number was used before, the controller114 can generate an alert signal to the user. In some embodiments, thecontroller 114 can shut down the processing apparatus 110 in response tothe detection of a used consumable 120. In some embodiments, thecontroller 114 can temporarily lock the processing system from use inresponse to the detection of a used consumable. In some embodiments, thecontroller 114 can generate and present a warning to the user, such asvia an audio and/or visual indicator, for example.

The pairing (also referred to as mating) between the processingapparatus 110 and the coffee pack 120 as facilitated by the tag reader115 can be generally referred to as digital pairing. In otherembodiments, the processing apparatus 110 can be physically paired withthe coffee pack 120. For example, the processing apparatus 110 mayinclude a number of receiving ports to receive the coffee pack 120 ofspecific geometry which can ensure proper batch sizing and other coffeequality attributes. In some embodiments, each receiving port may onlyreceive one type of coffee pack 120 and correspond to a specific set ofroasting instructions.

In some embodiments, the processing apparatus 110 includes a sensor(e.g. one of the sensors 116) configured to detect the pairing status ofthe receptacle 140. For example, if the sensor detects that a consumable120 is properly received by the receptacle, the controller 114 then candirect an opener to automatically open the consumable 120 and start theprocessing procedures.

In some embodiments, the processing apparatus 110 can include one ormore optional sensors 116 to monitor the operational or environmentalparameters. In some embodiments, the sensors 116 can provide real-time,periodic, and/or on-demand feedback information to the controller 114 toadjust the operational parameters. For example, the sensors 116 caninclude a temperature sensor and the controller 114 can be configured toincrease or decrease the roasting temperature based on the temperatureinformation provided by the sensors 116. In some embodiments, thetemperature sensor can be in direct contact with the substance tomeasure the temperature of the substance. In some embodiments, thetemperature sensor can be coupled to the wall of the processing chamber112 to measure the wall temperature as an indicator of the substancetemperature.

In some embodiments, the sensors 116 can include multiple temperaturesensors disposed at various locations in the processing apparatus 110.For example, a first temperature sensor can be disposed near the inletof the processing/roasting chamber 112 to measure the temperature ofinlet air into the chamber, a second temperature sensor can be disposednear the outlet of the roasting chamber 112 to measure the temperatureof the exhaust air from the chamber, and a third temperature sensor canbe disposed in the roasting chamber 112 to measure the air temperaturewithin the processing chamber 112. In some embodiments, the controller114 can consolidate and process the signals from all temperature sensorsto derive an accurate value of the substance temperature, i.e., of thecoffee beans during roasting.

In some embodiments, the sensors 116 can store the acquired parametersinto a memory. For example, the sensors 116 can measure and store thetemperature profile or curve applied during roasting. In someembodiments, the temperature curve can be sent back to the database 130and provide information for the service party to update the database 130if needed. In some embodiments, the temperature curve can be employed bythe user to find out his or her favorite roasting settings.

In some embodiments, the sensors 116 can include a humidity sensor tomeasure ambient humidity. The controller 114 may modify the processinginstructions based on the ambient humidity. For example, the controller114 may increase the processing temperature in response to high humidityin the environment. As another example, the controller 114 may increasethe airflow within the processing chamber 112 in response to highhumidity in the environment.

In some embodiments, the sensors 116 can include a humidity sensor totrack moisture content of the coffee beans during roasting over time soas to estimate the degree of roasting. In such instances, the humiditysensor can be disposed within the processing chamber 112 to detect thehumidity of air within the processing chamber 112. Based on the detectedhumidity, the controller 114 can change the operation parameter of theprocessing chamber 112.

In some embodiments, the sensors 116 can include a color sensor tomeasure the color of the substance in the processing chamber 112. Basedon the detected color, the controller 114 can determine the degree ofprocessing (e.g., degree of roasting) and accordingly adjust theoperation parameter of the processing chamber 112 (e.g., temperature orduration). In some embodiments, the color sensor is configured tomeasure a change of color of the substance. In some embodiments, thecolor sensor detects the color or color change using a laser. In someembodiments, the color sensor detects the color or color change using awhite light light-emitting diode (LED).

In some embodiments, the sensors 116 can include a location sensor (alsosometimes referred to as a location tracking device) to determine thephysical location of the processing chamber 112. In some embodiments,the location sensor is configured to measure an altitude of theprocessing chamber 112 and the controller 114 can modify the processinginstructions based on the altitude. For example, a higher altitude mayindicate a higher airflow rate. In some embodiments, the location sensorcan include a GPS receiver. In some embodiments, the location sensor caninclude an atmospheric pressure sensor or any other device to measurethe altitude.

In some embodiments, the various sensors 116 can be prioritized whenadjusting the operation parameter of the processing apparatus 110. Insome embodiments, during the processing of the substance contained inone consumable 120, the controller 114 may first rely on the temperaturesensor(s) to control operation of the processing chamber 112, and later(in the processing cycle) rely on the color sensor close to the end ofthe processing to control the processing chamber 112. For example, thecolor sensor may be used during about the last 15% of a processing cycle(e.g., about 15%, about 12%, about 10% or less, including any values andsub ranges in between). In some embodiments, the color sensor may beemployed during about the last 2 minutes of a processing cycle (e.g.,about 2 minutes, about 1.5 minute, about 1 minute, or less, includingany values and sub ranges in between).

In some embodiments, the processing apparatus 110 can employ a “multihopper” mode to load the green coffee beans and support sequentialroasting of multiple coffee packs 120 over a period of time. In thismode, the user can load the processing apparatus 110 with multiplecoffee packs 120 for roasting so that batches can be roastedcontinuously until the coffee supply runs out. For example, if one roastof 2 pounds of coffee takes 10 minutes, the multi hopper mode can allowfor 20 pounds of green coffee to be loaded in the hopper so that 10rounds of roasting could be run before the roaster needs any additionalhuman intervention. In this manner, while the apparatus 110 can beconfigured for small batch/single consumable operation, it is capable ofautomated processing of multiple batches over time with little or nointervention, thereby improving efficiency. In some embodiments,multiple coffee packs 120 can be simultaneously received by theprocessing apparatus 110, which roasts green coffee in one coffee pack120 at a given time. In some embodiments, a single coffee pack 120 cancontain a large amount of green coffee (e.g., greater than 20 lbs) andthe processing apparatus 110 is configured to process one portion (e.g.,less than 10 lbs) at a given time; said another way, the processingapparatus 110 can be configured to process less than the entirety of thegreen coffee in a single coffee pack 120 at a given time. In suchembodiments, the processing apparatus 120 can include a mechanism todetermine the weight of green coffee in the processing chamber 112. Insome embodiments, the mechanism can be configured to measure the weightof green coffee in the processing chamber 112 and/or in theholding/airlock chamber. In some embodiments, the mechanism can beconfigured to measure the duration of opening of a valve on theprocessing apparatus 112 and then estimate the weight of green coffeedispensed into the processing chamber 112 based on that duration and(optionally) a flow rate of green coffee. The flow rate can be estimatedusing any suitable technique for estimating solid flow streams, such asultrasonic waves or microwave radiation.

In some embodiments, the processing apparatus 110 includes a tray (alsosometimes referred to as a cooling tray) to receive the substance afterprocessing. In some embodiments, the receptacle 140, the processingchamber 112, and the cooling tray collectively define a common axis. Insuch instances, the substance can move under the force of gravity fromthe receptacle 140 to the processing chamber 112, and from theprocessing chamber 112 to the tray. In some embodiments, the processingapparatus 110 includes a gas source (e.g., air) to produce a gas flow(e.g. through an “air blade” or air nozzle) to facilitate the movementof the substance from the processing chamber 112 to the cooling tray.

In some embodiments, the processing apparatus 110 includes an agitatorremovable or fixedly coupled to the tray and configured to agitate thetray so as to increase the cooling efficiency. In some embodiments, theprocessing apparatus 110 includes a gas source coupled to the tray toproduce a gas flow passing through the tray to facilitate the cooling.In some embodiments, the tray is removably coupled in the processingapparatus 110. In such instances, a user can remove the tray anddispense the processed substance into another container (e.g., a bulkbin container that contains multiple roast batches). In addition, a usermay also use different trays to accommodate different substances.

In some embodiments, the processing apparatus 110 includes a filteroperably coupled to the tray and configured to remove particles, such ascoffee chaff generated during the roasting process, having a diameterless than a predetermined diameter. In some embodiments, thepredetermined diameter can be from about 0.1 mm to about 2 mm (e.g.,about 0.1 mm, about 0.2 mm, about 0.3 mm, about 0.5 mm, about 1 mm,about 1.5 mm, or about 2 mm, including any values and sub ranges inbetween).

In some embodiments, the processing apparatus 110 can include a multistage cooling system for the roasted coffee beans, which can be usefulwhen the apparatus 110 is operating in the multi-hopper mode asdescribed herein. In such embodiments, the processing apparatus 110 canallow a user to load multiple consumables (i.e., multiple coffee packs120), initiate a roast sequence, and then walk away for multiple batchesof coffee roasting. In such cases, the processing apparatus 110 caninclude a cooling system so that multiple roast batches can be cooled.The cooling system can include a receptacle for a removable bowl, suchthat when the bowl received a batch of roasted coffee beans, a user oranother mechanical component can swap out that bowl for another when thecoffee in that bowl has cooled sufficiently, and before the next batchof roasted coffee is completed.

In some embodiments, the consumable/coffee pack 120 can be manuallyopened by a user, and the user then pours the unroasted green beans fromthe consumable 120 into the processing chamber 112. In some embodiments,the processing apparatus 110 includes an opener to open the consumable120. In some embodiments, the opener is operably coupled to thereceptacle 140 such that when the consumable 120 is in place the openercan open the consumable 120 and release the substance. In someembodiments, the opener includes a blade configured to slice open thecontainer, and the processing chamber 112 receives the substance basedon the gravity-driven movement of the substance. In some embodiments,the opener includes a rotating wheel opener. In some embodiments, theopener includes a church key punch opener. In some embodiments, theopener includes a mechanism for opening a perforated box. More detailsabout openers are described below with reference to FIGS. 11A-11C,12A-12D, 13A-13D, and 18A-18G.

In some embodiments, the processing apparatus 110 includes a userinterface for a user to control the operation of the processingapparatus 110. In some embodiments, the user interface includes a touchscreen that is configured to display different operation modes of theprocessing apparatus 110. For example, the touch screen may beconfigured to display different roasting options (e.g., dark roast,medium roast, or light roast) and in response to selection by the user,the controller 114 can then adjust the processing instructions, such asroasting temperature and/or time, so as to achieve the selected roastingoption.

In some embodiments, the user interface includes a devicecommunicatively coupled to the controller 114. For example, the userinterface can include a tablet wirelessly connected to the controller.In another example, the user interface can include a smartphonewirelessly connected to the controller.

The following description illustrates the use of the platform 100 forcoffee roasting in greater detail, and in a typical use setting. It isunderstood that one of ordinary skill in the art can adapt the system100 to process any other substance that is provided in a taggedconsumable.

In some embodiments, the platform 100 can be adapted to perform on-site,benchtop/tabletop coffee roasting. In such instances, the processingapparatus 110 includes a processing apparatus 110 and the consumable 120includes a coffee pack 120 containing green coffee (i.e., unroastedcoffee beans). In some embodiments, the coffee pack 120 containspartially roasted coffee (sometimes also referred to as pre-roastedcoffee beans, or pre-treated coffee beans). Pre-treatment of the greencoffee can reduce the water content in the beans and therefore reducethe weight of the coffee. The reduction of the weight can accordinglyreduce shipping cost.

In some instances, a user (e.g., a coffee shop and/or an individualcustomer making coffee at home) associated with the processing apparatus110 operates the processing apparatus 110 to roast green coffee, whilethe third party provides the coffee pack 120 and maintains the database130. The service party can include, for example, a green coffee importeror distributor. The coffee pack 120 contains green coffee (sometimesalso referred to as raw coffee beans or unroasted coffee beans) and atag 125 providing roasting instructions (sometimes also referred to as aroast profile). The processing apparatus 110 further includes a roaster112 to roast green coffee, a controller 114 to control the operation ofthe processing apparatus 110, and a tag reader 115 to read the tag 125included in the coffee pack 120.

In operation, the user places the coffee pack 120 into the processingapparatus 110. The tag reader 115 in the processing apparatus 110 readsthe tag 125 and transmits the information in the tag 125 to thecontroller 114. The controller 114 then provides specific instructionsto direct the roaster 112 to roast the coffee beans contained in thecoffee pack 120 based on the information contained in the tag 125. Thespecific instructions can be acquired directly or indirectly from thedatabase 130, as described in more detail herein. Since the specificinstructions are provided by the service party and encoded in the coffeepack 120 which is ready for immediate use, the user can roast the greencoffee without developing any expertise in coffee roasting, therebyenabling a wide range of people to make freshly roasted coffee.

The processing apparatus 110 can employ a single hopper approach. Eachtime, the processing apparatus 110 receives one coffee pack 120 androasts the green coffee beans in the coffee pack 120. The processingapparatus 110 then stops operation until a second coffee pack 120 isprovided. In some embodiments, the roasting system can 110 can furtherinclude a loading structure (not shown in FIG. 1 ) to load the coffeebeans. In some embodiments, the loading structure can include frontendrobotic systems or arms. In some embodiments, the loading structure caninclude conveyor belts. In some embodiments, the loading structure caninclude pneumatic tubes using compressed air or vacuums.

To achieve the temperature over time curve T(t) included in the roastinginstructions, the processing apparatus 110 can include heating andcooling elements to modulate the roasting temperature and circulate thecoffee beans for uniform roasting. In some embodiments, the processingapparatus 110 can include convective heating and a fluidized bedtechnique for lofting the coffee beans during the roast process. In someembodiments, the processing apparatus 110 can include air blades or airnozzles for accelerating hot air velocity for roasting. In someembodiments, the processing apparatus 110 can use induction heating toroast the coffee beans. In some embodiments, the processing apparatus110 can use a combination of convective heating, conductive heat, andinduction heating to develop additional coffee flavor profiles duringthe roasting process. In some embodiments, an external heating sourcecan be used for the roast chamber and the coffee can be mechanicallycirculated in the roast chamber. The speed or degree of mechanicalagitation can also be varied.

In some embodiments, the roaster 112 in the processing apparatus 110 caninclude a retail-scale automated coffee roaster, which can be sized tofit a regular-sized coffee shop or kitchen. For example, the footprintof the roaster 112 can be less than 6 feet×6 feet, less than 5 feet×5feet, or less than 4 feet×4 feet. These dimensions can allow most coffeeshops, grocery stores, bakeries and other retailers to carry out theirown roasting and serve freshly roasted coffee.

In some embodiments, the roaster 112 can include a table-top coffeeroaster, which can be placed on a counter. In such instances, thefootprint of the roaster 112 can be, for example, less than 3 feet×3feet.

In some embodiments, the roaster 112 in the processing apparatus 110 caninclude a counter-top coffee roaster, which can be conveniently placedin a home kitchen. For example, the footprint of the roaster 112 can beless than 1 foot×1 foot. These dimensions can allow individual users toroast and serve coffee at home.

As discussed above, the coffee pack 120 is usually provided by a serviceparty. In some embodiments, the service party can receive large packs ofgreen coffee of the same type. For example, each package of the greencoffee can be about 40 kg to about 70 kg. The service party can then usea small portion of the green coffee for test roasting so as to determinethe roasting instructions for the remaining portion of the green coffeein the same large pack or lot.

In some embodiments, the service party provides all the roastinginstructions for the user so as to allow fully automated roasting of theprocessing apparatus 110. In some embodiments, the service partyprovides a formula for the user to calculate a customized roastinginstruction. For example, the service party can provide a formula takinginto account the environmental parameters (e.g., ambient temperature andhumidity) and the user can plug in these environmental parameters so asto generate the customized roasting instruction. In some embodiments,the service party can provide a set of roasting instructions, each ofwhich corresponds to a roasting preference (e.g., light roast, mediumroast, or dark roast). The user can then select the preference.

Once the roasting instructions are acquired, the service party cantransmit the roasting instructions to the database 130. In someembodiments, the database 130 can include a cloud database such that theuser can connect to the database 130 anywhere in the world. In someembodiments, the cloud database can perform periodical synchronizationwith the user's processing apparatus 110.

In some embodiments, the service party includes the roastinginstructions in the tag 125 included in the coffee pack 120. In someembodiments, the service party includes a serial number in the tag 125and transmits roasting instructions corresponding to the serial numberto the database 130. In such instances, the user can first read theserial number and then consult with the database 130 to retrieve thecorresponding roasting instructions. In some embodiments, the serviceparty can include any other identification information in the tag 125 soas to allow the user to retrieve the appropriate roasting instructions.

In some embodiments, the user can consult with the database 130 toretrieve roasting instructions each time after reading the tag 125 on acoffee pack 120. In some embodiments, the user can store somefrequently-used roasting instructions in a local memory and consult withthe local memory after reading the tag 125 to retrieve roastinginstructions.

In some embodiments, the platform 100 allows the user to use asmartphone and a cloud based application executing thereon toconveniently manage the integrated coffee roasting. In some embodiments,the user can use the smartphone to order unroasted coffee beans from theservice party. In some embodiments, the user can use the smartphone toread the tag 125 on the coffee pack 120 (e.g., using the camera in thesmartphone). In some embodiments, the user can use the smartphone toretrieve roasting instructions from the database 130 based oninformation read from the tag 125. In some embodiments, the user can usethe smartphone to remotely control the roaster 112 by sending roastinginstructions to the roaster 112. In some embodiments, the user can usethe smartphone to retrieve brewing instructions to brew the roastedcoffee roasted by the processing apparatus 110. The brewing instructionscan be provided by the service party or another party.

In some embodiments, the user can use the smartphone to order greencoffee and the order can include roasting instructions electronicallytransmitted to the smartphone upon the placement of the order. In suchinstances, the user may not need to read the tag 125 or the coffee pack120 may not include the tag 125.

The platform 100 has several advantages compared to conventional coffeeroasting methods. The platform 100 is an integrated, consumable-basedcoffee roasting system. Within coffee roasting, there are the largeformat roasters as described previously and there are a few smaller,“retail scale” roasters. For example, there are several commerciallyavailable small retail scale roasters that are semi-automated, havelimited system controls for tuning roast parameters, with installedcosts in the range of $25,000. Therefore, machines of this type becomecost prohibitive for many retailers. In contrast, the platform 100 canprovide users with significant upfront capital and ongoing laborsavings. The platform can also provide enhanced quality and consistency,by automatically replicating the desired roast profile for each roastedbatch.

The platform 100 allows wireless connectivity between the user and theservice party. In some embodiments, the wireless communication canfacilitate tracking of the execution of roast protocols. For example,the user can transmit the measured temperature profile T(t) to theservice party and the service party can estimate whether the desiredtemperature profile T(t) is faithfully executed. In some embodiments,the wireless communication can facilitate remote tracking of coffeeroasts, allowing real-time instructions from the service party ifneeded. In some embodiments, the wireless connectivity allows the userto carry out consumable inventory management.

Furthermore, the platform 100 allows the user to store and accessinformation related to the coffees they purchase or prefer through acloud based application. With the platform 100, the user can eventuallyselect their preferred green coffee, order roasted coffee to theirspecification through the system, and have the coffee and roast tailoredto their preferences.

In some embodiments, the platform 100 can be used for coffee roasting.In some embodiments, the platform 100 can be used for on-site roastingof nuts, such as chestnuts, hazelnuts, almond, cashews, pistachio, andwalnuts, among others. In some embodiments, the platform 100 can be usedfor roasting cacao.

FIG. 2 illustrates a method 200 of integrated coffee roasting, accordingto embodiments. The method 200 can, in some embodiments, be executed bythe processing apparatus 110, or a structurally/functionally similarvariant thereof. At step 210 of the method 200, a service party receivesconsumables (e.g., sacks) containing green coffee beans (referred to ascoffee X). In some embodiments, the service party can receive importedgreen coffee directly at the port. In some embodiments, the serviceparty can receive the green coffee from a distributor. In someembodiments, each sack can include about 40 kg to about 70 kg of greencoffee.

At step 220 of the method 200, a portion of coffee is roasted in theservice party's facility by a roastmaster, who determines and generatesthe specific roast parameters included in a temperature time curve T(t).In some embodiments, the roastmaster can use a roasting system that issubstantially identical to the processing apparatus 110 shown in FIG. 1. In some embodiments, the roastmaster can use a roasting systemdifferent from the processing apparatus 110 shown in FIG. 1 . Forexample, the roasting system used by the roastmaster can include anintegrated color sensor to facilitate the generation of roasterparameters. In some embodiments, the color sensor and the controller canform a roast degree analyzer to determine the degree of roasting basedon the color.

In some embodiments, the temperature time curve T(t) can depend onblower setting, heater temperature, and exhaust temperature, amongothers. At step 220, the service party also stores the roast parametersin an appropriate data format.

At step 230 of the method 200, the service party places the green coffeebeans into small packages for the user and includes roastinginstructions or roasting instruction identification information into atag included in the small packages. In some embodiments, coffee X can beloaded into a consumable filling machine and consumables are produced.In some embodiments, the roast parameters can be stored in RFID memoryon the consumable. In some embodiments, the roast parameters are storedin a cloud database.

Also at step 230, the service party can estimate appropriate roast sizecorresponding to the physical characteristics of the roaster that wouldbe used to roast the green coffee. In some embodiments, the amount ofgreen coffee in each package can be about 500 grams to about 2000 grams(e.g., about 500 grams, about 600 grams, about 750 grams, about 1000grams, about 1200 grams, about 1400 grams, about 1500 grams, about 1750grams, or about 2000 grams, including any values and sub ranges inbetween).

In some embodiments, the amount of roasted coffee in each package can bekept the same by taking in account variations in the density andmoisture content in green coffee. In such instances, the green coffee ineach package may have different weights. In some embodiments, the amountof coffee after roasting can be about 300 grams to about 2000 grams(e.g., about 300 grams, about 500 grams, about 600 grams, about 750grams, about 1000 grams, about 1200 grams, about 1400 grams, about 1500grams, about 1750 grams, or about 2000 grams, including any values andsub ranges in between).

At step 240 of the method 200, the user receives and loads theconsumable(s) into a roaster (e.g., the processing apparatus 110 shownin FIG. 1 ). Loading the consumable can be achieved in any suitablemanner. In some embodiments, the consumable can be a flexible packagewith a specific geometry and made from a coffee industry standardbarrier film. In some embodiments, the consumable can be “loaded” intothe roaster by manually opening the bag and pouring the green coffeeinto the coffee loading hopper. In some embodiments, a coffee packagehaving a flexible/compliant casing can be coupled to a more rigid handleor frame that might enable easier loading and/or physical mating withthe machine via clips, tracks, or any other means known in the art.

In some embodiments, the consumable, once loaded into the roaster, canbe sliced open by a cutting mechanism integrated with the roaster, whichcan then eject the “used” consumable components (e.g., cut open bagplastic and frame/handle piece).

In some embodiments, the consumable couples with the roaster, forpurposes of transferring the green coffee and contents of the consumableto the roast chamber, using any suitable mechanical interface(s). Insome embodiments, the interface can include a zipper. In someembodiments, the interface can include a mechanical interface. In someembodiments, the interface can include an interlocking interface with amale and female component. In some embodiments, the interface caninclude mechanical tearing along a perforation.

At step 250 of the method 200, the roasting system as used by the userreads the tag included in the consumable to retrieve roastinginstructions. In some embodiments, the consumable digitally mates withthe roasting system (e.g., via RFID, barcode, optical recognition,and/or the like), which allows the roasting system to recognize thespecifics of the consumable, the contents of the consumable, andinformation related to the contents of the consumable (e.g., coffeetype, origin, age, roast profile, etc.). These specifics then allow theroasting system to set the roast parameters by matching the green coffeeto the same coffee that was test roasted at headquarters by the roastmaster.

In some embodiments, the tag is read after the consumable is loaded intothe roaster, i.e. 250 is after 240. In some embodiments, the tag can beread by an external device before the package is loaded into theroaster. The external device then transmits the information on the tagto the roaster so as to control the roaster to roast the green coffee,i.e. 250 precedes 240. The tag reader can also be connected to, or beformed on, an interface of the roaster, instead of on the consumablereceptacle (e.g., the receptacle 140).

At step 260 of the method 200, the roasting system roasts the coffeefollowing the roasting instructions retrieved at step 250. In someembodiments, the roasting system can roast batches in sequences. Thiscan be achieved through a multi-chamber hopper and a multistage coolingtray. In some embodiments, the consumables can be designed so that theyare connected to each other in a manner that allows them to be loadedcontinuously. In some embodiments, the roasting system can automaticallyweigh out the batches from a large hopper or from a multi-batchconsumable. In some embodiments, the roasting system can measure theweight of green coffee for each roast. For example, the roasting systemcan be configured to roast less than 15 lbs of green coffee at a giventime, and to accordingly close the hopper once it determines that about15 lbs of green coffee is already dispensed into the roasting chamber.

FIG. 3 illustrates a schematic of an example environment/system 300 forintegrated coffee roasting, including additional detail on theproduction of consumables at a service party facility. Unless notedotherwise, components similarly named to those disclosed in FIGS. 1-2can be structurally and/or functionally similar. The system 300 includesa service party facility 310, a customer site 320, and a database 330.In some embodiments, the database 330 may encompass cloud-based storage.In the service party facility 310, large sacks of green coffee arereceived, as indicated by the block 311. A first portion of the greencoffee is then made into samples as shown in block 312. A roast mastertest roasts the sample green coffee and sets the roast parameters forthe rest of the green coffee, as shown in block 313. The roasterparameters are then transmitted to the database 330 (which can besimilar to the database 130). The service party facility 310 alsoexecutes a cloud based roaster application 314 that allows the roastmaster to manipulate and track roast profiles.

The green coffee that is not sampled for test roasting is then loadedinto a consumable packing system 315 in the service party facility 310to be packaged into small consumables/coffee packs. The packing systemmay incorporate one or more cleaning stations that substantially or atleast partially removes, among other things, green coffee dust, stones,metal objects and other undesirable matter that may have been includedin the bulk sacks of coffee. The packing system 315 can debulk the greencoffee and dose predetermined portions of green coffee into eachconsumable. The packing system 315 also includes a form-fill machine topackage the green coffee into flexible packages, or other consumablecanisters, for the user. The packing system 315 also puts oninjection-molded frame, or alternative labels, that containsidentification information for each small pack. The small packs are thensent to an inventory management system 316, which manages the shippingof the small packs. In some embodiments, the small packs are furtherpackaged into case packs.

The service party facility 310 also includes a quality control system(QCS) 317 to match the roast results of a given set of roast parameterswith sensory expectations that were established from baseline analysis(sometimes referred to as cuppings). The QCS 317 is in communicationwith the database 330, which negotiates the exchange of informationbetween all components of the platform 300. For example, the database330 is connected to the roasting profile setting block 313 and eachindividual roasters 322. In such instances, the roastmaster transmitsthe roasting profile(s) for a given lot of green coffee beans to thedatabase 330, and users who would like to roast green coffee beans inthat lot can then retrieve the roasting profiles and then roast thegreen coffee accordingly.

The database 330 is also communicably coupled to the packaging system315. Therefore, the identification information (e.g., serial number) ofeach package can be saved into the database 330. Users can then read theidentification information on the tag attached to each package andretrieve the roasting profiles corresponding to the identificationinformation from the database 330. Furthermore, the database 330 isconnected to the inventory management system 316 and a user app 321, inwhich case users can see which green coffee is available for purchaseand purchase the green coffee via their personal devices (e.g.,smartphone, tablet, personal computer, etc.).

In the customer site 320, the customer receives the small packs from theservice party as indicated by the block 323. Individual small packs arethen picked up for roasting as shown in block 324. The roasting iscarried out by a roaster 322, which can be provided by the serviceparty. The roaster 322 is physically and/or digitally mated with thecoffee packs and can retrieve roasting instructions from the database330. The roaster 322 can also upload post-roast information back to thedatabase 330. Upon finishing the roasting, the roaster 322 outputsroasted coffee 325 for the user. The customer site 320 also includes acustomer app 321 that allows for browsing and ordering of green coffee,as well as managing all aspects of the consumer experiences. Thecustomer app 321 is in communication with the database 330 and theroaster 322 to achieve these functions.

The small packs prepared by the service party are also referred to asconsumables. As described herein, a consumable can be used in any of thesystems and methods in this application. For example, the consumable canbe used as the consumable 120 in the system 100 shown in FIG. 1 , thecoffee consumable in the systems 300 and 400 shown in FIGS. 3 and 4 ,respectively, and/or in the apparatus 800 shown in FIGS. 8A-8D.

Using consumables as disclosed herein ensures roasting consistency bycommunicating the appropriate roast profile to user roasters over anetwork and/or via tags on the consumable. The consumable package sizecan be based on the roaster's single batch size, guaranteeing that theright amount of green coffee is dispensed into the roaster every time.Green coffee quality is maintained throughout storage and distributionthrough the consumable's package barrier properties. The roaster canautomatically open the consumable, saving retail-level labor andminimizing exposure to green coffee dust.

In some embodiments, the consumable package size depends on the batchsize of the roaster. For example, in some embodiments, each batch canproduce about 1.5 pounds of roasted coffee and the service partyprovides roasters that are configured to produce about 1.5 pounds ofroasted coffee in a given round of roasting. Green coffee beans vary indensity and moisture content, and therefore the volume and weight of theconsumable input to achieve the 1.5 pound roasted coffee output may alsovary. For example, the density of green coffee can vary between about0.63 g/ml and 0.71 g/ml, and roast loss (due to loss of moisture, anddry matter reductions) can be from about 13% to about 17%. Accordingly,to produce 680 grams of roasted coffee, the green coffee in a consumablecan vary from about 764 g to about 819 g, and the volume of theconsumable can vary from about 1107 ml to about 1300 ml. In someembodiments, a consumable can include additional headspace toaccommodate different volume requirements.

In some embodiments, a consumable is configured as a rectangular boxwith a square cross section (see, e.g., FIGS. 10A-10B). In someembodiments, the length of the rectangular box can be about 8 inches orless (e.g., about 8 inches, about 7 inches, about 6 inches, about 5inches, or less, including any values and sub ranges in between). Insome embodiments, other shapes, such as round, elliptical, or irregularpackages, can also be used.

In some embodiments, multiple consumables can be packaged together toform a package (also sometimes referred to as a “casepack”), and eachpackage can weigh between 25 lbs and 40 lbs for ease of handling. Thepackage can be designed to maximize the transportation efficiency of a48″×40″ pallet, and can contain 12 or 16 consumables. In someembodiments, a smaller package might be desirable from the perspectiveof storage in the shop and the number of SKUs that are anticipated.

In some embodiments, the consumable can include FDA-approved materials.In some embodiments, the consumable can also be constructed of materialsthat have been proven not to impart off-flavors over the consumable'sshelf life, e.g., that do not impart undesirable flavors to green coffeebeans stored therein.

To maintain quality, the consumable packaging can provide a suitablebarrier against ambient conditions. In some embodiments, the oxygentransmission rate (OTR), in cc/m2/day at 0.1 Mpa and 23° C., can beabout 4.28 or less. In some embodiments, the water vapor transmissionrate (WVTR), in g/m2/day at 0.1 Mpa and 38° C., can be about 2.14 orless. In some embodiments, a sealed or vacuum sealed liner at thepackage level can be added to improve the barrier properties.

When properly packaged, the total shelf life of green coffee beans fromarrival until roasting can be approximately 1 year. In some embodiments,green coffee beans can be filled into the consumable upon arrival fromorigin, so the consumable can be designed to maintain green coffee forup to 1 years with no more than the standard degradation it wouldotherwise experience if, for example, it had been stored in a coffeeindustry standard sealed plastic bag liner.

In some embodiments, the labeling of the consumable can include one ormore of the following information: Brand Name, Coffee/Blend Name, FlavorDescription, Net Post-Roast Weight (ounces and grams); Packed On Date,Company Name, City, State and Zip Code. In some embodiments, thelabeling of the consumable may include the following additionalinformation: Origin, Producer, Variety, Process, Elevation, CompanyPhone Number, Company URL, and any appropriate claims, such as “USDAOrganic” and “Fair Trade.”

FIG. 4 shows a schematic of another example system 400 for integratedcoffee roasting with additional detail on a user facility. The system400 includes a database 430 (e.g., similar to the database 330)maintained by a service party and a consumer app 420, which allows theconsumer to browse coffees and follow the roast in real time, as well asto allow the consumer to customize the roast by adjusting the roastparameters. The system 400 also includes a customer site 410. In thecustomer site 410, a user receives coffee packs containing green coffeebeans from the service party, as indicated by block 412. The user thenpicks individual small packs for roasting, as indicated by block 413.The customer site 410 further includes a customer app 411, incommunication with the database 430, to help the user operate theroasting process by, for example, ordering coffee beans from the serviceparty.

The roasting of the green coffee is performed by a roaster machine 440,which includes a set of sensors, such as a barometric sensor 441 a, atemperature sensor 441 b, a humidity sensor 441 c, and any other sensors441 d as disclosed herein in FIGS. 1-2 . The sensors 441 a to 441 d arein communication with a roast controller 442 (e.g., similar to thecontroller 114, also sometimes referred to as the roast brain). Theroast controller 442 includes a roast profile/parameter controller 442a, a roast initiator/monitor controller 442 b, a roast calibrationalgorithm 442 c, and a roast brain stem 442 d.

The roast profile/parameter controller 442 a is in communication withthe database 430 to download roast information from the database 430.The roast profile/parameter controller 442 a also sends post-roastinformation back to the database 430. The post-roast information can beused by the service party as feedback to update the database 430 orimprove the roasting instructions in the database 430. In addition, theroast profile/parameter controller 442 a is also in communication with aconsumable unloader and bean recognizer 445 a, which can read tags onthe consumables to acquire identification information of the consumablesand directs the roast profile/parameter controller 442 a to match andretrieve the corresponding roast profile to the identificationinformation.

The roast initiator/monitor controller 442 b is coupled to a startbutton 443. The user can press the button 443 and initiate the roastingprocess. The roast initiator/monitor controller 442 b is also coupled toa bean hopper 445 b and a sensing system 445 c coupled to the roastingchamber. The sensing system 445 c can provide real-time roastingparameters for the roast initiator/monitor controller 442 b to monitorthe roasting process. The sensing system 445 c is also coupled to amulti-roast cooling tray 445 d and acquires operation parameters of themulti-roast cooling tray 445 d from the roast initiator/monitorcontroller 442 b.

The roast calibration algorithm 442 c is in communication with thesensors 441 a to 441 d to develop the roasting instructions that takeinto account environmental information such as pressure (acquired by thebarometric sensor 441 a), ambient temperature (acquired by thetemperature sensor 44 ab), and ambient humidity (acquired by thehumidity sensor 441 c). The roast calibration algorithm 442 c canconsolidate these data, in combination with the data retrieved from thedatabase 430, into actual roasting instructions, which are provided tothe roast brain stem 442 d.

The roast brain stem 442 d is in communication with a heater/blowercontroller 446 a, which controls the operation of heaters 446 b andblowers 446 c (also referred to as coolers) in the roaster machine 440.The heater/blower controller 446 a receives instructions from the roastbrain stem 442 d and then instructs the heaters 446 b and blowers 446 cto achieve the temperature-time curve specified in the instructions.

In some embodiments, the consumer app 420 is distinct from the customerapp 411. For example, the consumer can refer to the customer's customer,in which case the customer can be a grocery chain operating the roastingmachine 440 and the consumer can be one of their shoppers. In someembodiments, the consumer app 420 can sense that the consumer (throughgeo-location) is on the premises of the grocery store (e.g., customer'ssite 410) and ask if the consumer wants to initiate a roast of the“Special Consumer Blend”. The consumer app 420 can also monitor theroast and give a notification when it is ready.

FIG. 5A is an example user interface 500 usable by a user of aroasting/processing apparatus (e.g., the apparatus 110) to facilitateon-site coffee roasting, according to embodiments. The interface 500includes a field 510 displaying the roasting profile 515 that iscurrently used. In some embodiments, the roasting profile 515 ismanifested as temperature as a function of time (e.g. temperaturecurve). The field 510 also displays the current timing point 516 on theroasting curve 515 such that a user can conveniently find out thecurrent state of roasting and the amount of time remaining. Theinterface 500 also includes a field 520 displaying the bean temperature,which can be acquired by, for example, sensors operably coupled to theroaster (e.g., sensors 116 shown in FIG. 1 ). In addition, the interface500 also includes a field 530 displaying the amount of time afterroasting starts (i.e., time lapse).

The operation status (e.g. normal) and/or any alert (e.g., reuse ofconsumable detected, overheat detected, or emission error detected,etc.) can be displayed in a field 540 in the interface 500. The user canalso input any notes into the field 540, such as any modification fromthe processing instructions received from the database 430, or anycustomized operation parameters of the roaster. These notes can betransmitted back to the database 430 for various purposes. For example,the roastmaster may study the users' notes and update the roastingprofiles saved on the database 430. Or a processor connected to thedatabase 430 can consolidate the user's' notes and generate new roastingprofiles using machine learning techniques. Furthermore, other users mayview and download the user's' notes and apply them to their own roastingcycles.

FIG. 5B illustrates a field 550 that can be included in the interface500. The field 550 displays a roasting profile manifested by atemperature-time curve 552. The field 550 also displays a curve 554illustrating the rate of rise of the temperature-time curve 552.

FIG. 6 illustrates a method 600 of substance processing. In someembodiments, the method 600 can be executed by the apparatus 110 shownin FIG. 1 and described above, or a structurally and functionallysimilar variant thereof. The method includes, at 610, receiving acontainer containing a substance for processing. The container includesa readable tag to contain processing information associated with thesubstance. At an optional step 620, the readable tag is read to retrievethe processing information. The method also includes generatingprocessing instructions at 630. The processing instructions aregenerated using a controller based at least in part on the processinginformation read from the readable tag and additional processinginformation received from a remote device. At 640, the substance isintroduced into a processing chamber and at 650 the substance isprocessed based at least in part on the processing instructions.

In some embodiments, the substance includes green coffee packaged insmall batches. For example, each container contains about 3 lbs or lessof green coffee (e.g., about 3 lbs, about 2.5 lbs, about 2 lbs, about1.5 lbs, about 1 lbs, or less, including any values and sub ranges inbetween). In such instances, a user can manage the time period betweenroasting and brewing coffee so as to maintain the freshness of thecoffee.

In some embodiments, reading the tag is achieved using a tag readeroperably coupled to a receptacle that is configured to receive thecontainer. In such instances, when the container is in place, the tagreader can automatically read the tag to retrieve the processinginformation. In some embodiments, a sensor can be used to detect thepresence of the container. In response to detection of an appropriatecontainer in the receptacle, a controller can direct the tag reader toread the tag. In some embodiments, the tag is read using an externaldevice separate from the processing chamber. The external device thentransmits the processing information to the controller, which in turngenerates the processing instructions.

Various types of tag readers can be used in the method 600, regardlessof whether the tag reader is an external device or an integratedcomponent in the roasting device. In some embodiments, the tag readerincludes a radio frequency identification (RFID) reader. In someembodiments, the tag reader includes a barcode scanner. In someembodiments, the tag reader includes a QR code scanner.

The tag can be configured to contain various types of information. Insome embodiments, the tag includes address information about thecontainer and/or the substance within the container, and the controlleris configured to generate the processing instructions by retrieving atleast some of the processing instructions from a memory operably coupledto the controller based on the address information in the readable tag.In some embodiments, the address information can be used to retrieve theprocessing instructions from a remote server.

In some embodiments, the tag includes processing instructions that canbe directly executed by the controller, which in turn controls theprocessing chamber to process the substance. In some embodiments, thetag includes a desired roast level of the substance after processing(e.g., type of coffee roast, such as, dark roast, medium roast, or lightroast). The desired roast level is then referenced by the controller toadjust the additional processing information received from the remoteserver so as to generate the processing instructions.

In some embodiments, the substance is directly delivered from thecontainer to the processing chamber. In some embodiments, the substanceis disposed into a hopper, which then delivers the substance into theprocessing chamber. In such instances, the substance can be delivered tothe processing chamber in a more controlled manner. A valve can bedisposed between the hopper and the processing chamber to control thesubstance delivery (also referred to as substance feeding).

In some embodiments, the substance is disposed into an intermediatechamber (e.g., an airlock chamber), which in turn delivers the substanceinto the processing chamber. The intermediate chamber similarly allowssmooth flow of the substance from the container to the processingchamber. A first valve can be disposed between the container and theintermediate chamber, and a second valve can be disposed between theintermediate chamber and the processing chamber. The two valves cancollectively control the substance flow from the container to theprocessing chamber.

In some embodiments, the roasting system can include both a hopper andan intermediate chamber. In such instances, a first valve can bepositioned between the hopper and the intermediate chamber, and a secondvalve can be positioned between the intermediate chamber and theprocessing chamber.

In any of the above embodiments, the valves can be automaticallycontrolled by a controller. For example, when the system detects thatthe processing chamber is properly pre-heated, the controller can openthe valve to feed the processing chamber with the substance. The systemmay also monitor the amount of substance in the processing chamber andclose the valve when sufficient amount of substance (e.g., about 3 lbsor less) is already in the processing chamber.

In some embodiments, the processing chamber includes a roasting chamberconfigured to roast the substance via heat application. In someembodiments, the substance is roasted via conductive heat application onthe substance. In some embodiments, the substance is roasted viaconvective heat application on the substance. In some embodiments, thesubstance is roasted via both convective heat application and conductiveheat application on the substance. In some embodiments, the substance isroasted via inductive heat application on the substance.

In some embodiments, the method 600 further includes generating a signalindicative of the temperature of the substance in the roasting chamberand adjusting at least one operation parameter of the roasting chamberbased on the signal. In some embodiments, the operation parameter isadjusted to be compliant with the processing instructions. In someembodiments, the operation parameter includes the temperature of thesubstance. In some embodiments, the operation parameter includes theflow rate of hot air fed into the processing chamber.

The substance temperature can be measured or estimated in various ways.In some embodiments, a temperature sensor is positioned at an inlet ofthe roasting chamber to measure the temperature of the inlet air, whichis indicative of the energy to be applied to the substance. In someembodiments, a temperature sensor is positioned in contact with thesubstance which is can be indicative of the substance temperature. Insome embodiments, a temperature sensor is positioned at an outlet of theroasting chamber to measure the temperature of the exhaust air and therelationship of this air temperature to the substance temperature canalso be indicative of the energy transferred to the substance. In someembodiments, a temperature sensor can be positioned inside the roastingchamber to measure the air temperature within the roasting chamber ormeasure the wall temperature of the roasting chamber.

In some embodiments, multiple sensors can be used. For example, onetemperature sensor can be disposed near the inlet, one temperaturesensor can be disposed at the outlet, and one or more temperaturesensors can be disposed within the roasting chamber. The controller cancollect signals from all temperature sensors and derive the accuratetemperature of the substance.

In addition, the collection of the measurements by the temperaturesensors can also be used for device diagnostics. For example, iftemperature sensors do not achieve and/or record predeterminedtemperature set points during certain periods of the roast process, thesystem may determine that a fault condition is met, and notify a user ofthe system.

In some embodiments, a color sensor is employed to detect the color ofthe substance in the roasting chamber and the color can be indicative ofthe stage of roasting. The controller can then adjust the operationparameter(s) of the roasting chamber based on the detected color. Insome embodiments, the color detector includes a laser. In someembodiments, the color detector includes a white light LED.

In some embodiments, both the color and temperature of the substance aremonitored. The controller relies on the substance temperature to adjustthe operation parameters during the early stage of the roasting andrelies on the substance color to adjust the operation parameters duringthe later stages of the roasting. For example, the controller can relyon the substance color to control the roasting at the end of theroasting so as to achieve the desired finish color. The desired finishcolor can be based on numeric color values. For example, the colorvalues could be based on the Specialty Coffee Association Roast ColorClassification System ranging from very light to very dark. In someembodiments, for a given color value, more than one temperature-timeprofile can be used to achieve the given color value.

In some embodiments, the method 600 further includes measuring variousenvironmental parameters, which can be used to adjust the processinginstructions (or the roasting profiles). In some embodiments, the method600 includes measuring the humidity in the environment surrounding theroasting device. In some embodiments, the method 600 includes measuringthe location of the roasting device using, for example, a GPS, anatmospheric pressure sensor, or any other proper detectors. The locationof the roasting device can include the altitude of the roasting device.The altitude information is then used by the controller to adjust theprocessing instructions (e.g., increasing the airflow as the altitudeincreases).

In some embodiments, the substance is disposed into the processingchamber manually by a user. For example, a user can scan the readabletag using an external device or a scanner mounted to the exteriorsurface/casing of the apparatus and then pours the substance into theprocessing chamber. The external device transmits the processinginformation in the tag to the controller for subsequent generation ofprocessing instructions.

In some embodiments, an opener is used to open the container and deliverthe substance from the container to the processing chamber (or thehopper, or the intermediate chamber, if applicable). In someembodiments, the opener includes a blade to slice open the container andthe substance can move into the processing chamber under gravity force.In some embodiments, the opener includes a can opener. In someembodiments, the opener includes a sliding punch with cutting edgeopener. In some embodiments, the opener includes an articulating barbflap opener.

In some embodiments, the method 600 further includes dispensing thesubstance after processing into a cooling tray and reducing thetemperature of the substance using the cooling tray. The cooling of thesubstance can be achieved by, for example, air cooling. An agitator canalso be used to agitate the cooling tray to increase the cooling rate.In some embodiments, the agitation is achieved using a vibratory motor,which vibrates the cooling tray and levels the roasted coffee to achieveeven cooling. In some embodiments, the agitation is achieved using anagitator arm or a stirring arm to level and mix the roasted coffee toachieve even cooling. In some embodiments, a filter can be used togetherwith the cooling tray to remove particles below a threshold size. Thethreshold size can be, for example, from about 0.1 mm to about 2 mm(e.g., about 0.1 mm, about 0.2 mm, about 0.3 mm, about 0.5 mm, about 1mm, about 1.5 mm, or about 2 mm, including any values and sub ranges inbetween).

In some embodiments, the method further includes displaying, on a userinterface, at least two processing modes to process the substance. Thedisplay is further configured to receive a selection from a user and thecontroller can adjust the processing instructions based on the user'sselection. In some embodiments, the processing modes include desiredroast levels of the substance after processing, such as type of coffeeroast, light roast, medium roast, dark roast.

In some embodiments, the user interface includes a touch screen for bothmode display and mode selection. In some embodiments, the user interfacecan be a tablet, a smartphone, a personal computer, or any otherappropriate device. This device can be digitally connected to thecontroller and the user can conveniently control the operation of theroasting device from this device.

In some embodiments, the container is received by a receptacle having amating mechanism to secure the container. In some embodiments, themating mechanism includes a physical mating mechanism, such as akey-and-lock structure, to receive only certain type of containers. Oncethe correct container is in place, the system can detect the presence ofthe container using a sensor. In addition, a tag reader can be triggeredto read the tag on the container and/or an opener can be triggered toopen the container and dispense the substance in the container into theprocessing chamber.

In some embodiments, once the correct container is in place, a fullyautomated processing procedure is initiated. In this process, thecontainer is opened by an opener and the substance is dispensed into theprocessing chamber automatically. The controller receives the processinginformation from a tag reader and then generates the processinginstructions based on the processing information and additionalprocessing information from the remote server. The processing chamber ispre-heated also upon the detection of the container in the receptacle.The controller then directs the processing chamber to process thesubstance in compliance with the processing instructions. The processedsubstance is then removed from the processing chamber and placed in acooling tray for subsequent use (e.g., grinding of coffee).

In some embodiments, the controller saves processing information fromeach tag into a database and compares subsequent processing informationwith the database. If the current processing information was detectedbefore, the controller then generates an alert signal to the userindicating possible reuse of the container. In some embodiments, thecontroller can lock the roasting device to block the substance fromentering the processing chamber in response to detection of a reusedcontainer.

FIG. 7 illustrates a block diagram of a distributed system 700 forsubstance processing. The system 700 includes a plurality of roastingdevices 720 a, 702 b, and 702 c, each of which includes a respectivereceptacle (722 a/722 b/722 c) configured to receive a container. Insome embodiments, each of the roasting devices 720 a, 720 b, and 720 ccan be structurally and/or functionally similar to the apparatus 100shown in FIG. 1 and described above. The container includes thesubstance for processing and further includes a tag having processinginformation. Each device (720 a/720 b/720 c) also includes a respectivetag reader (724 a/724 b/724 c) configured to read the processinginformation from the tag on the container and a respective processingchamber (726 a/726 b/726 c) to process the substance.

The system 700 also includes a computing device 710 (also sometimesreferred to as a central server 710), which in turn includes a memory712 configured to store a plurality of roasting instructions. Eachroasting instruction has corresponding processing information associatedtherewith. The computing device 710 also includes a communicationinterface 716 operably coupled to the memory 712 and a processor 714operably coupled to the memory 712 and the communication interface 716.The processor 714 is configured to execute executable instructions toreceive the processing attributes via the communication interface 716from at least one roasting device (720 a, 720 b, and/or 720 c). Theprocessor 714 then retrieves the roasting instruction corresponding tothe processing attributes from the memory 712 and controls thecommunication interface 716 to transmit that roasting instruction to theat least one roasting device (720 a, 720 b, and/or 720 c).

In some embodiments, the communication interface 716 of the computingdevice 710 includes a digital communication interface, such as awireless interface. Accordingly, the communication between the computingdevice 710 and the roasting devices 720 a, 720 b, and 720 c can beachieved via wireless connection. In some embodiments, the computingdevice 710 can include a cloud server.

In some embodiments, the computing device 710 is in communication with amaster roasting device (not shown) operated by an entity such as aroastmaster, or another separate device. For each lot of green coffee,the roastmaster takes out a sample and roasts the sample using themaster roasting device, producing a roasting profile for the lot ofcoffee. During the test roasting, the operation parameter(s) of themaster roasting device can be recorded by the computing device 710 andused for generating the roasting profile. In some embodiments, theoperation parameter includes the temperature profile as a function oftime. In some embodiments, the operation parameter(s) can also betransmitted to the computing device 710 and can be made available forusers to retrieve and download to their own roasting devices (720 a, 720b, and 720 c) to customize their roasting. In some embodiments, eachroasting device 720 a, 720 b, and 720 c can transmit its respectiveroasting Logs to the computing device 710, which can make the Logsavailable for other users to use.

In some embodiments, the computing device 710 is configured to generateat least part of the roasting profile. For example, the processor 714can receive at least one attribute of green coffee being roasted in themaster coffee roaster and generate a roasting instruction based on theattribute of the green coffee. The attribute of the green coffee caninclude, for example, origin, weight, harvesting time, and/or thevariety of the green coffee.

In some embodiments, the communication interface 716 of the computingdevice 710 can receive operation parameters from the roasting devices720 a, 720 b, and/or 720 c. The processor 714 then saves the operationparameters into the memory 712 and generates one or more roastinginstructions based at least in part on the operation parameters. In thismanner, users can participate in the process of generating the roastingprofiles.

In some embodiments, in addition to operation parameters, users can alsotransmit other information to the computing device 710. For example,users can upload users' comments about the green coffee, the roastingprocess, and/or the roasted coffee. These comments can be considered bythe roastmaster when evaluating the roasting profiles.

In some embodiments, the computing device 710 is in real-timecommunication with the roasting device 720 a, 720 b, and 720 c. In someembodiments, the processor 714 receives at least one environmentalparameter from a roasting device 720 a, 720 b, or 720 c, generates a newroasting instruction based at least in part on the environmentalparameter, and then transmits the new roasting instruction back to thesending device to instruct the roasting. In this way, users can acquirereal-time instruction from the computing device 710. In someembodiments, the environmental parameter includes at least one of a roomtemperature, a humidity, or the geographic location of the roastingdevice.

FIGS. 8A-8D illustrate a compact roaster 800 that can be used forroasting green coffee or other suitable products. The roaster 800includes a receptacle 810 configured to receive a coffee packagecontaining green coffee, a roasting chamber 820 to roast the greencoffee, and an output port 830 to release the roasted coffee to acooling tray 840. The receptacle 810, the roasting chamber 820, and thecooling tray 840 collectively define a common axis 801. In suchinstances, the green coffee beans can move to the roasting chamber 820from the receptacle 810 via force of gravity (once the consumable/coffeepackage is opened). The roasted coffee can also move to the cooling tray840 under gravity force. This configuration can also increase thecompactness of the roaster 800, allowing convenient use in a wide rangeof environments, such as retailer stores, home kitchens, and offices.

A window 825 (also sometimes referred to as a sightglass 825) isincluded on the roasting chamber 820 and can allow a user to visuallymonitor the roasting process by observing, for example, the color of thecoffee beans in the roasting chamber 820. Alternatively or additionally,color sensors can be used to monitor the roasting process. A mesh grillpattern 870 is applied on the surfaces of the compact roaster 800 andcan be configured for ventilation. The top of the compact roaster 800can also include a mesh grill pattern 822 as shown in FIG. 8D to provideadditional ventilation.

A handle 880 (also referred to as a lever 880) is disposed below thereceptacle 810 to control the operation of the roaster 800. In someembodiments, the handle 880 can be used to initiate a fully automatedroasting process. For example, a user can pull the handle towardthemselves (see, e.g., FIGS. 8D, 10A and 10B) and start the roastingprocess. In some embodiments, the handle 880 can be used to secure thecoffee package in the receptacle 810 and/or turn on an opener configuredto open the coffee package.

The roaster 800 also includes a base section 850 to support thereceptacle 810, the roasting chamber 820, and the cooling tray 840. Thebase section 850 can also be configured to contain electroniccomponents, such as processor, memory, and communication interface,among others. In addition, the wall of the base section 850 can alsoinclude several indicators 852 and 854. For example, the first indicator852 can be used to display the temperature of the coffee beans withinthe roasting chamber. The second indicator 854 can include three LEDlights showing the status of the roaster 800. For example, the indicator854 can show that the roaster is “Roasting In Process,” “Cooling InProcess,” and “Roasting Completed” using the three LED lights. Any otherarrangements of the LED lights can also be used. The wall of the basesection 850 can also include a power button 856 that can be configuredas the main power switch of the roaster. A green light shown on thepower switch 856 can indicate that the roaster 800 is powered on. Insome embodiments, additional indicators may be used to alert a user oferrors by displaying a red light. The roaster 800 also includes fourlegs 860 to support the roaster 800.

In FIGS. 8A-8D, the cross section of the receptacle 810 has arectangular shape. Accordingly, the cross section of the coffee packagecan also have a rectangular shape, i.e., the coffee package/consumablecan have a cuboid shape. In some embodiments, the cross section can haveother shapes, such as round, elliptical, square, or any other suitableshape.

In some embodiments, the roaster 800 can be configured to operate in anambient temperature from about 4° C. to about 40° C. In someembodiments, altitude information of the roaster 800 can be entered uponinstallation through the communication interface. The altitudeinformation can be used to determine and/or adjust the roast profile.Alternatively, a GPS receiver can be used to determine the location ofthe roaster 800.

In some embodiments, the roaster 800 can include one or morecommunication interfaces to connect the roaster 800 to the Internet. Insome embodiments, a RJ45 connector can be used for direct Ethernetconnection. In some embodiments, a Wi-Fi interface can be included toconnect the roaster 800 to the Internet via wireless connections. Insome embodiments, the roaster 800 can include a Bluetooth interface,which can be used for mobile App setting of roaster profiles.

In some embodiments, base section 850 (or any other sections of theroaster 800) can be configured for various types of displays andindicators. In some embodiments, the roaster 800 can include anindicator (e.g., an LED light) to show that the consumable is loaded andready for processing. For example, a red color from the LED light canindicate error (e.g., because of reused container or other inappropriatecontainers), a yellow color can indicate that the roaster 800 isscanning the tag on the consumable and setting roasting profiles, and ablinking green light can indicate that the it is ready to beginroasting.

In some embodiments, the roaster 800 can include an indicator to displaythe status of roasting. For example, a red light can indicate error, ayellow light can indicate that the roasting chamber 820 is underpre-heating, and a green light can indicate that the roasting chamber820 is functioning properly.

In some embodiments, the roaster 800 can include an indicator to displaythe status of cooling. For example, a red light can indicate error, agreen light can indicate that the cooling is under progress, and a bluelight can indicate that the cooling is done and the roasted coffee beanscan be removed for further processing, such as grinding.

In some embodiments, the roaster 800 can allow various user controlinputs. In some embodiments, a user can pull down the lever 880 totrigger the roaster 800 to open the consumable and start roasting. Insome embodiments, a user can push down the lever 880 to set the roaster800 into a maintenance mode from idle, allowing opening of front panelto service roast chamber 820. In some embodiments, a user can push anemergency stop button to shut down power instantly. In some embodiments,a user can use a mobile app for choosing roasting profiles andquantities for inventory management.

The roaster 800 can include various types of sensors to monitor theroasting process. In some embodiments, the roaster 800 includes a beantemperature sensor to measure the coffee bean temperature. The sensorcan be placed within the roasting chamber 820 to be fully immersed inthe bean mass and out of the influence of the airflow. In someembodiments, the roaster 800 can include blower intake temperaturesensor configured for measuring ambient temperature at intake of theroaster 800. In some embodiments, the roaster 800 can include a heaterinlet temperature sensor configured for measuring heater inlettemperature. In some embodiments, the roaster 800 includes a heateroutlet temperature sensor configured for measuring heater outlettemperature.

In some embodiments, the roaster 800 can include an exhaust temperaturesensor located in the exhaust flow at the chamber exhaust port andconfigured for measuring the exhaust temperature. In some embodiments,the roaster 800 can include a roasting chamber inlet temperature sensorconfigured for measuring the inlet air temperature with minimal flowinterference. In some embodiments, the roaster 800 can include a coolingtray temperature sensor configured for measuring cooling traytemperature. In some embodiments, the roaster 800 can include an ambientair temperature sensor configured for measuring ambient temperature.

In some embodiments, the roaster 800 can include a sensor to detect thepresence of a consumable. The sensor can include, for example, athrough-beam sensor or a reflective sensor. In some embodiments, theroaster 800 can include a sensor to detect the presence (or the absence)of the cooling tray 840. The sensor can use light transmission orreflection for the detection. In some embodiments, the roaster 800 caninclude a sensor to measure the cooling tray level (e.g., weight ofroasted beans in the cooling tray).

In some embodiments, the roaster 800 can include a sensor to detect thepresence or the absence of a chaff collector to ensure the chaffcollector is ready to receive chaff. Coffee chaff is the dried skin on acoffee bean and usually comes off during the roasting process. The chaffis usually much lighter than the coffee beans such that it may spreadaround the roasting system and interfere with the normal operation ofthe roasting system. In some embodiments, the roaster 800 can include asensor to measure the chaff collector level (e.g., whether the collectorneeds to be emptied). In some embodiments, the chaff collector caninclude a cyclonic separator to separate the chaff from the coffeebeans.

In some embodiments, the roaster 800 can include a sensor to detectwhether the front panel of the roaster 800 is open. In some embodiments,the roaster 800 can include a sensor to detect whether the back panel ofthe roaster 800 is open. In some embodiments, the roaster 800 caninclude one or more pressure sensors to detect system leaks andblockages.

In some embodiments, the roaster 800 can be configured to fit and standstably on a typical café counter, i.e. a counter-top coffee roaster. Forexample, the dimensions of the roaster 800 can be about 30 inches(Width)×24 inches (Height)×22 inches (Depth) or less. In someembodiments, the weight of the roaster 800 (without coffee green) can beabout 200 lbs or less (e.g., about 200 lbs, about 175 lbs, about 150lbs, about 125 lbs, about 100 lbs, or less, including any values and subranges in between).

The output system in the roaster 800 includes the output port 830 andthe cooling tray 840. This system is configured to perform one or moreof the following functions, including receiving hot roasted coffee beansdischarged from the roasting chamber 820, cooling the roasted coffeebeans in the cooling tray 840, drawing away smoke emitted by the roastedcoffee beans, agitating the roasted coffee to settle the bean level,filter out unwanted particulates (principally chaff) with a serviceablefilter and routing smoke/exhaust fumes into main roaster exhaust.

In some embodiments, the cooling tray 840 is configured to hold at least680 grams of roasted coffee beans, which is usually the standard batchsize. Accordingly, the consumable fed into the receptacle 810 caninclude green coffee that is expected to yield about 680 g of roastedcoffee. In some embodiments, the volume of the cooling tray 840 can beabout 2000 mL or greater. In some embodiments, the cooling tray 840 isconfigured to reduce or avoid spilling of roasted coffee beans when theroasted coffee beans are dumped into the cooling tray 840. In someembodiments, during discharge, the roasting chamber 820 can bepressurized, and the coffee beans may be ejected with more force thanjust gravity. Accordingly, the cooling tray 840 can be configured tohave a larger size to receive the roasted coffee beans. In someembodiments, the cooling tray 840 is configured to withstand regularexposure to roasted coffee beans with a surface temperature of about230° C. or more.

In some embodiments, the cooling tray 840 is configured to cool down theroasted coffee beans evenly from about 230° C. to ambient roomtemperature in about 4 minutes or less (e.g., about 4 minutes, about 3minutes, about 2 minutes, or less, including any values and sub rangesin between). In some embodiments, the roaster 800 can include a blowerto facilitate the cooling via forced air convection. In someembodiments, the roaster 800 can include a stirring arm or paddle toagitate the cooling tray 840. In some embodiments, the roaster 800 caninclude a vibratory motor to agitate the cooling tray 840 when smallbatch sizes are used (e.g., about 2 lbs or less). In some embodiments,an agitator arm or a stirring arm can be used to level and mix theroasted coffee to achieve even cooling of the substance. In someembodiments, the removable cooling tray is designed to facilitatepouring the roasted coffee beans into another container. For instance,in some embodiments the cooling tray may include a spout. In someembodiments, the cooling tray may have a handle. In some embodiments,the cooling tray may have finger grips.

FIGS. 9A and 9B illustrate two cooling trays that can be used in theroaster 800 shown in FIGS. 8A-8D. FIG. 9A illustrates a cooling tray1101 including a side wall 1111 and a filter 1121 formed at the bottomof the tray 1101. The side wall 1111 is made of an opaque material, suchas a metal, ceramic, plastic, etc. FIG. 9B illustrates a cooling tray1102 including a side wall 1112 and a filter 1122 formed at the bottomof the tray 1102. The side wall 1112 is made of a transparent material,such as glass, plastic, or polymer, among others. The side wall isdesigned with three rounded corners and one pointed corner. The pointedcorner can function as a spout that facilitates pouring the roastedbeans into another container. In FIGS. 9A and 9B, the filters 1121 and1122 are configured to remove particles having dimensions less than apre-determined values while the cooling air is drawn through the coolingtray. In some embodiments, the filters 1121 and 1122 can be configuredto remove particles in the range from about 0.1 mm to about 1 mm.

FIGS. 10A and 10B illustrate a coffee roasting system 1200 including amechanism to open consumables 1220 within a roaster 1210. In FIG. 10A,the consumable 1220 is ready to be placed into a receptacle 1215 of theroaster 1210, which can be substantially identical to the roaster 800shown in FIGS. 8A-8D and detailed descriptions are not repeated here. InFIG. 10B, the consumable 1220 is positioned in the receptacle. The shapeand dimensions of the consumable 1220 are configured to fit the shapeand dimensions of the receptacle 1215, such that when the consumable1220 is placed into the receptacle 1215, the consumable 1220 is securedand held by the receptacle 1215. The roaster 1210 also includes anopener (see FIGS. 13A-17C) operably coupled to the receptacle 1215 andconfigured to open the consumable 1220 when it is received by thereceptacle 1215.

FIGS. 11A-11C illustrate a can opener 1300 using a sliding punch withcutting wheel mechanism. The can opener 1300 is used for automaticallyopening consumables 1301. The can opener 1300 includes a lever 1310 anda punch 1320 disposed at the tip of the lever 1310. In operation, thepunch 1320 is rotated to break open a corner of the consumable 1301 asillustrated in FIGS. 11A and 11B. The lever 1310 then slides along theedge of the consumable 1301 and cuts open the entire bottom edge (shownin FIG. 11C) using the cutting wheel 1330. The green coffee in theconsumable 1301 is dispensed through the cut edge by gravity.

FIGS. 12A-12D illustrates an opener 1500 for automatically opening a box1501 with a perforated flap opening 1511. The opener 1500 includes alever 1525 with a cross mounted plunger assembly 1510. The cross mountedplunger assembly 1510 has a blunt tip 1514 disposed at the distal end ofa handle 1512. The blunt tip 1514 pierces the apex of the boxperforation 1511 when the lever 1525 is rotated toward the box 1501. Thecross mounted plunger assembly 1510 is subsequently pushed forward,which drives an articulating barb 1516 down (shown in FIG. 12D),trapping the box flap between the articulating barb 1516 and lever 1525.The box flap is opened and the green coffee is released as the lever1525 rotates away from the face of the box 1501.

FIGS. 13A-13D illustrates an opener 1600 using a sliding punch with acutting edge according to embodiments. The opener 1600 is also referredto a Church Key 1600. The Church Key 1600 includes a lever 1610 and apunch 1620 disposed at one end of the lever 1610. The Church key rotatesaround and slides on a shaft 1630 as shown in FIG. 13A. One edge of thepunch has a cutting edge 1622. In operation, the punch 1620 is rotatedthrough the corner of a consumable 1601 by rotating the lever 1610around shaft 1630. The punch 1620 cuts open a small opening 1611 in theconsumable 1601, as shown in FIG. 13B. The cutting edge 1622 of theChurch Key 1600 then cuts along the bottom edge of the consumable so asto open the entire edge as shown in FIGS. 13C and 13D. The green coffeedispenses from the consumable by gravity along the cut edge.

FIG. 17 is a block diagram of a roaster 1700 which may be structurallyand/or functionally similar to any of the roasters described in detailherein. During use, the roaster 1700 may include an air path 1702 and abean path 1704 through the system 1700. For example, air may enter aninlet 1710 of an air intake filter 1720. The air intake filter 1720 maybe coupled to a blower 1730 that pressurizes the ambient air. The blower1730 may be coupled to a heat exchanger 1740, which may be configured toreceive the pressurized ambient air from an outlet of the blower 1730.The heat exchanger 1740 may be coupled to a heater 1750 and a catalyticoxidizer 1780. The heat exchanger 1740 may be further configured toreceive heated air from the catalytic oxidizer 1780. The heated air andambient air may mix within the heat exchanger 1740 and may be outputeither from the first heater 1750 or from the exhaust 1742. The heatexchanger 1740 may be configured to modulate the temperature and flowrate of air output to the roast chamber 1760. The first heater 1750 maybe coupled to the roast chamber 1760 and may be configured to heatand/or pressurize the air received from the heat exchanger 1740. Thefirst heater 1750 may output air into the roast chamber 1760 via anozzle such as described in more detail herein.

A consumable, such as a container 1706 of beans, may be loaded 1706 intothe system 1700. The contents of the container 1706 may be input intothe roast chamber 1760 at a predetermined time (e.g., 10 minutes per 2lb. batch) during the roasting process. When roasting of the beans hasbeen completed, the beans may be output from the roast chamber 1760 forcooling on a tray 1790, for example. Returning to the air path 1702,heated air may be output from the roast chamber 1760 to a cyclonicseparator 1770 configured to separate the chaff from the beans and thento a second heater 1752. The second heater 1752 may be configured toincrease air temperature (e.g., between about 650° F. and about 700° F.)for catalysis in the catalytic oxidizer 1780. An output of the secondheater 1752 may be coupled to an input of a catalytic oxidizer 1780.Accordingly, heated air within the roaster 1700 may be reused so as toreduce energy consumption and the exhaust of heated air into the ambientenvironment.

FIGS. 14A-14B illustrate a compact roaster 1400 that can be used forroasting green coffee or other suitable substances. As shown in FIG.14A, the roaster 1400 may include a roasting chamber 1410 configured toroast green coffee and a nozzle 1420 coupled to the roasting chamber1410. The nozzle 1420 may be configured to provide pressurized andheated air to the roasting chamber 1410 at a predetermined flow rate andtemperature as described in detail herein. The nozzle 1420 may becoupled to a heat exchanger 1430 as shown in FIG. 14B. The heatexchanger 1430 may be coupled to a blower 1450 and a catalytic oxidizer1460, and may be configured for heat recovery where hot air from theroasting chamber may be reused and directed back into the catalyticoxidizer, thereby reducing power consumption. Generally, the nozzle 1420may be configured to precisely modulate the air temperature for a roastprocess such that most of the energy added to the ambient air isprovided by the heat exchanger, and not by the nozzle. The heatexchanger 1430 may be a passive component (e.g., stainless steelcross-flow) configured to receive heated airflow from the catalyticoxidizer 1420 and blower 1450. The heat exchanger 1430 and blower 1450may be coupled via a set of inlets 1440 including a blower inlet 1442and cooling inlet 1444. In some embodiments, the catalytic oxidizer 1420may be configured to receiver exhaust from the chamber 1410 and increasethe air temperature to between about 650° F. and about 700° F. In someother embodiments, the heat exchanger 1430 may be an active componentsuch as a rotary heat exchanger.

The nozzle 1420 as described herein may improve the efficiency of heatedairflow into a roasting chamber such that a smaller blower may be usedthat may (in turn) use less energy, and which may aid in minimizing thephysical size of a compact, benchtop roaster. It should be appreciatedthat without considering the presence of beans (or other substances)within the roasting chamber, about 95% of pressure losses occur at thenozzle such that flow performance largely depends on nozzle design.

FIG. 15A illustrates a perspective view of a roasting chamber 1510coupled to an outlet 1520 and a nozzle 1530. As best illustrated in FIG.15B, the cross-sectional area of the nozzle 1530 may decrease from aproximal end 1532 to distal end 1534 of the nozzle 1530. The nozzle 1530may include a nozzle exhaust 1540 at a distal end. The nozzle 1530 maygradually transition from a proximal portion having a circularcross-section to a distal portion (e.g., nozzle exhaust 1540) having arectangular cross-section. In some embodiments, the transition from acircular cross-section to rectangular cross-section may occur across theentire length of the nozzle. In some embodiments, the distal end of thenozzle 1530 may have a diameter of between about 1 inch and 3 inches.The diameter at the distal end of the nozzle 1530 may be about 2 inches.

In some embodiments, a roaster may include a cyclonic separatorconfigured to remove a chaff of a coffee bean. In some of theseembodiments, a longitudinal axis of the cyclonic separator may besubstantially parallel to ground (e.g., a horizontal plane) during use.The cyclonic separator may be coupled to a catalytic oxidizer asdescribed herein such that air may flow from the cyclonic separator tothe catalytic oxidizer.

In some embodiments, the nozzle exhaust 1540 may have a curve of betweenabout 90° and about 135° configured to promote Gortler vortices suchthat high speed hot air output from nozzle exhaust 1540 may uniform(e.g., even pressure distribution) as it enters into a roasting chamber1510. Gortler vortices are secondary flows that may appear in boundarylayer flow along a concave wall. The nozzle 1530 may reducerecirculation of air and allow for more uniform lofting of the beansalong a length of the nozzle 1530. For example, Gortler vortices may begenerated along the lateral sides of the nozzle exhaust 1540 and mayenergize airflow in those regions to increase mixing and reduce frictionwith the walls of the nozzle exhaust 1540 so as to better match airflowcharacteristics of a central portion of the nozzle exhaust 1540. Thatis, airflow within the nozzle 1530 may be accelerated monotonouslywithout regions of separation or recirculation. Furthermore, the curvedshape of the nozzle exhaust 1540 may reduce “dead zones” and promotemixing of air near the side walls of the roasting chamber 1510. Theshape of the nozzle as described herein may also allow the roaster to bemore compact and allow miniaturization relative to a linear nozzle thatwould create a larger footprint and/or casing. FIG. 15C illustrates across-sectional view and provides an example set of dimensions of thenozzle 1530, nozzle exhaust 1540, and roasting chamber 1510.

FIG. 16 is an illustrative plot (1600) of flow rate and pressure dropwhere an operating envelope 1620 is defined by the intersection of achamber resistance curve 1610 with a blower performance curve 1630. Forexample, the nozzle provides a flow rate at the points defined byoperating envelope 1620 along the chamber resistance curve 1610corresponding to the strength of the blower as defined by the blowerperformance curves 1630.

FIGS. 18A-18G illustrate methods of opening a consumable container 1820.In some embodiments, a consumable container 1820 may include a tag (notshown). The tag (e.g., bar code, QR code, RFID tag, and/or any otherappropriate identifier) may be read by a tag reader (not shown) that maygenerate processing instructions based on the processing informationcontained within the tag. The processing instructions may includeinstructions and/or authorization to open the container 1820. In FIG.18A, the system may be configured to form a cut 1802 in a container 1820using a container opener 1810 (e.g., blade, knife, cutter, edge,protrusion, opener). The container opener 1820 may move relative to astationary container 1820 (using a linear actuator) or the container1820 may move relative to a stationary container opener 1820 such asthrough user insertion.

As illustrated in FIG. 18B, the container opener 1810 may be configuredto create at step 1804 an opening 1830 in the container 1820. Forexample, the opening 1830 may extend along a length of a longitudinaledge formed by two side walls of the container 1820. In otherembodiments, the opening 1830 may be any suitable shape and dimension.For example, the opening 1830 may have a shape such as circle, polygon,C-shape, V-shape, zig-zag pattern, combinations thereof, and the like.The opening 1830 may include any number of openings that are disposed inany manner such as parallel, intersecting, perpendicular, and/or angledrelative to each other, combinations thereof, and the like. The opening1830 may be disposed on one or more of an edge, bottom surface, and sidewalls of the container 1820.

FIG. 18C illustrates a plunger 1840 configured to contact at step 1806 acontainer 1820 having an opening 1830 in order to expand the size of theopening 1830 and urge the contents 1850 (e.g., coffee beans) of thecontainer 1820 to fall out of the opening 1830. The process of deformingthe container 1820 repeatedly may agitate the contents 1850 of thecontainer 1820 efficiently to remove substantially all of the contents1850. The plunger 1840 may be coupled to an actuator 1842 (e.g., linearactuator) that may be configured to advance the plunger 1840 to contactand deform 1806 the container 1820 such that the opening 1830 may expand(e.g., one or more sides of the container 1820 bulge out). In somecases, retraction of the plunger 1840 may allow the container 1820 toreturn substantially to its previous shape and reduce the size of theopening 1830. In some embodiments, advancement and retraction of theplunger 1840 may be repeated until substantially all of the contents ofthe container 1810 are removed (e.g., fall out due to gravity) from thecontainer 1820.

In some embodiments, a set of plungers 1840 (not shown) may contact anddeform at step 1806 one or more sides of the box 1820. The shape of theplunger 1840 is not limited. For example, the contact surface of theplunger 1840 may be blunt in order to deform the container 1820 withoutcreating another opening. In other embodiments, the shape of the plunger1840 may be configured to deform the container 1820 and create anotheropening. For example, the plunger may have a protrusion (e.g., spike) orsharp edges. In some embodiments, the plunger 1840 may be configured tocontact the same portion of the container 1820 or different portions ofthe container 1820 with each actuation cycle.

FIG. 18D illustrates the container 1820 with a side wall removed forclarity to show the state of the container 1820 throughout the differentsteps of the opening process. The box is unopened at step 1800, cut openalong a longitudinal edge at step 1804, and cut open and furtherdeformed at step 1806. FIGS. 18E and 18F are respective side and bottomviews of the plunger 1840 deforming 1806 the container 1820 such thatthe opening 1830 expands to allow the contents 1850 of the container1820 to naturally fall out.

As illustrated in FIG. 18G, in some embodiments, a container 1820 may beplaced into a frame 1860 to aid and/or guide an opener 1810 in creatingan opening in the container 1820. The frame 1860 may be configured tohold the container 1820 in a desired position. In some embodiments, theframe 1860 may define an index 1862 (e.g., hole, cut-out, space,opening) that a portion of an opener 1810 may fit into in order tocreate an opening in the container 1820 held on the frame 1860. Forexample, an opener 1810 may slide into index 1862 and cut an openinginto a predetermined corner of the container 1820. The frame 1860 mayensure that the container 1820 is at a desired position (e.g., alignedwith a corner and edge) for the opener 1810 to create an opening.

While various inventive embodiments have been described and illustratedherein, those of ordinary skill in the art will readily envision avariety of other means and/or structures for performing the functionand/or obtaining the results and/or one or more of the advantagesdescribed herein, and each of such variations and/or modifications isdeemed to be within the scope of the inventive embodiments describedherein. More generally, those skilled in the art will readily appreciatethat all parameters, dimensions, materials, and configurations describedherein are meant to be exemplary and that the actual parameters,dimensions, materials, and/or configurations will depend upon thespecific application or applications for which the inventive teachingsis/are used. Those skilled in the art will recognize, or be able toascertain using no more than routine experimentation, many equivalentsto the specific inventive embodiments described herein. It is,therefore, to be understood that the foregoing embodiments are presentedby way of example only and that, within the scope of the appended claimsand equivalents thereto, inventive embodiments may be practicedotherwise than as specifically described and claimed. Inventiveembodiments of the present disclosure are directed to each individualfeature, system, article, material, kit, and/or method described herein.In addition, any combination of two or more such features, systems,articles, materials, kits, and/or methods, if such features, systems,articles, materials, kits, and/or methods are not mutually inconsistent,is included within the inventive scope of the present disclosure.

The above-described embodiments can be implemented in any of numerousways. For example, embodiments of designing and making the technologydisclosed herein may be implemented using hardware, software or acombination thereof. When implemented in software, the software code canbe executed on any suitable processor or collection of processors,whether provided in a single computer or distributed among multiplecomputers.

Further, it should be appreciated that a computer may be embodied in anyof a number of forms, such as a rack-mounted computer, a desktopcomputer, a laptop computer, or a tablet computer. Additionally, acomputer may be embedded in a device not generally regarded as acomputer but with suitable processing capabilities, including a PersonalDigital Assistant (PDA), a smart phone or any other suitable portable orfixed electronic device.

Also, a computer may have one or more input and output devices. Thesedevices can be used, among other things, to present a user interface,such as the Example interface illustrated in FIG. 5 . Examples of outputdevices that can be used to provide a user interface include printers ordisplay screens for visual presentation of output and speakers or othersound generating devices for audible presentation of output. Examples ofinput devices that can be used for a user interface include keyboards,and pointing devices, such as mice, touch pads, and digitizing tablets.As another example, a computer may receive input information throughspeech recognition or in other audible format.

Such computers may be interconnected by one or more networks in anysuitable form, including a local area network or a wide area network,such as an enterprise network, and intelligent network (IN) or theInternet. Such networks may be based on any suitable technology and mayoperate according to any suitable protocol and may include wirelessnetworks, wired networks or fiber optic networks.

The various methods or processes (outlined herein may be coded assoftware that is executable on one or more processors that employ anyone of a variety of operating systems or platforms. Additionally, suchsoftware may be written using any of a number of suitable programminglanguages and/or programming or scripting tools, and also may becompiled as executable machine language code or intermediate code thatis executed on a framework or virtual machine.

In this respect, various inventive concepts may be embodied as acomputer readable storage medium (or multiple computer readable storagemedia) (e.g., a computer memory, one or more floppy discs, compactdiscs, optical discs, magnetic tapes, flash memories, circuitconfigurations in Field Programmable Gate Arrays or other semiconductordevices, or other non-transitory medium or tangible computer storagemedium) encoded with one or more programs that, when executed on one ormore computers or other processors, perform methods that implement thevarious embodiments disclosed herein. The computer readable medium ormedia can be transportable, such that the program or programs storedthereon can be loaded onto one or more different computers or otherprocessors to implement various aspects of the embodiments disclosedherein.

The terms “program” or “software” are used herein in a generic sense torefer to any type of computer code or set of computer-executableinstructions that can be employed to program a computer or otherprocessor to implement various aspects of embodiments as discussedabove. Additionally, it should be appreciated that according to oneaspect, one or more computer programs that when executed perform methodsdisclosed herein need not reside on a single computer or processor, butmay be distributed in a modular fashion amongst a number of differentcomputers or processors to implement various aspects disclosed herein.

Computer-executable instructions may be in many forms, such as programmodules, executed by one or more computers or other devices. Generally,program modules include routines, programs, objects, components, datastructures, etc. that perform particular tasks or implement particularabstract data types. Typically the functionality of the program modulesmay be combined or distributed as desired in various embodiments.

Also, data structures may be stored in computer-readable media in anysuitable form. For simplicity of illustration, data structures may beshown to have fields that are related through location in the datastructure. Such relationships may likewise be achieved by assigningstorage for the fields with locations in a computer-readable medium thatconvey relationship between the fields. However, any suitable mechanismmay be used to establish a relationship between information in fields ofa data structure, including through the use of pointers, tags or othermechanisms that establish relationship between data elements.

Also, various inventive concepts may be embodied as one or more methods,of which an example has been provided. The acts performed as part of themethod may be ordered in any suitable way. Accordingly, embodiments maybe constructed in which acts are performed in an order different thanillustrated, which may include performing some acts simultaneously, eventhough shown as sequential acts in illustrative embodiments.

All definitions, as defined and used herein, should be understood tocontrol over dictionary definitions, definitions in documentsincorporated by reference, and/or ordinary meanings of the definedterms.

The indefinite articles “a” and “an,” as used herein in thespecification and in the claims, unless clearly indicated to thecontrary, should be understood to mean “at least one.”

The phrase “and/or,” as used herein in the specification and in theclaims, should be understood to mean “either or both” of the elements soconjoined, i.e., elements that are conjunctively present in some casesand disjunctively present in other cases. Multiple elements listed with“and/or” should be construed in the same fashion, i.e., “one or more” ofthe elements so conjoined. Other elements may optionally be presentother than the elements specifically identified by the “and/or” clause,whether related or unrelated to those elements specifically identified.Thus, as a non-limiting example, a reference to “A and/or B”, when usedin conjunction with open-ended language such as “comprising” can refer,in one embodiment, to A only (optionally including elements other thanB); in another embodiment, to B only (optionally including elementsother than A); in yet another embodiment, to both A and B (optionallyincluding other elements); etc.

As used herein in the specification and in the claims, “or” should beunderstood to have the same meaning as “and/or” as defined above. Forexample, when separating items in a list, “or” or “and/or” shall beinterpreted as being inclusive, i.e., the inclusion of at least one, butalso including more than one, of a number or list of elements, and,optionally, additional unlisted items. Only terms clearly indicated tothe contrary, such as “only one of” or “exactly one of,” or, when usedin the claims, “consisting of,” will refer to the inclusion of exactlyone element of a number or list of elements. In general, the term “or”as used herein shall only be interpreted as indicating exclusivealternatives (i.e., “one or the other but not both”) when preceded byterms of exclusivity, such as “either,” “one of” “only one of” or“exactly one of.” “Consisting essentially of,” when used in the claims,shall have its ordinary meaning as used in the field of patent law.

As used herein in the specification and in the claims, the phrase “atleast one,” in reference to a list of one or more elements, should beunderstood to mean at least one element selected from any one or more ofthe elements in the list of elements, but not necessarily including atleast one of each and every element specifically listed within the listof elements and not excluding any combinations of elements in the listof elements. This definition also allows that elements may optionally bepresent other than the elements specifically identified within the listof elements to which the phrase “at least one” refers, whether relatedor unrelated to those elements specifically identified. Thus, as anon-limiting example, “at least one of A and B” (or, equivalently, “atleast one of A or B,” or, equivalently “at least one of A and/or B”) canrefer, in one embodiment, to at least one, optionally including morethan one, A, with no B present (and optionally including elements otherthan B); in another embodiment, to at least one, optionally includingmore than one, B, with no A present (and optionally including elementsother than A); in yet another embodiment, to at least one, optionallyincluding more than one, A, and at least one, optionally including morethan one, B (and optionally including other elements); etc.

In the claims, as well as in the specification above, all transitionalphrases such as “comprising,” “including,” “carrying,” “having,”“containing,” “involving,” “holding,” “composed of,” and the like are tobe understood to be open-ended, i.e., to mean including but not limitedto. Only the transitional phrases “consisting of” and “consistingessentially of” shall be closed or semi-closed transitional phrases,respectively, as set forth in the United States Patent Office Manual ofPatent Examining Procedures, Section 2111.03.

We claim:
 1. A substance processing system, comprising: a blower coupled to a recirculating air path, the blower configured to provide a flow of air to the recirculating air path; a roasting chamber coupled to the recirculating air path; a nozzle coupled to the recirculating air path between the blower and the roasting chamber, the nozzle configured to accelerate the flow of air; and a catalytic oxidizer coupled to the recirculating air path to receive the flow of air after the flow of air is output from the roasting chamber.
 2. The system of claim 1, wherein the roasting chamber is configured to mechanically circulate a substance within the roasting chamber.
 3. The system of claim 1, further comprising: a cyclonic separator coupled to the recirculating air path and configured to separate portions of a substance after the substance is processed in the roasting chamber and before the flow of air enters the catalytic oxidizer.
 4. The system of claim 1, further comprising: a heater coupled to the recirculating air path, the heater configured to increase a temperature of the flow of air before the flow of air is output to the catalytic oxidizer.
 5. The system of claim 1, further comprising: a heat exchanger coupled to the recirculating air path, the heat exchanger configured to receive the flow of air from the blower, the heat exchanger configured to receive the flow of air from the catalytic oxidizer coupled to the recirculating air path.
 6. The system of claim 1, wherein the nozzle is configured to accelerate air monotonously through a cross-sectional area of the nozzle.
 7. The system of claim 1, wherein the nozzle defines a lumen that decreases in cross-sectional area from a proximal end of the nozzle to a distal end of the nozzle, the nozzle configured to output the flow of air from the distal end of the nozzle into the roasting chamber.
 8. The system of claim 1, wherein the nozzle includes a curve of between 90° and 135° between a proximal end of the nozzle and a distal end of the nozzle.
 9. The system of claim 1, wherein the nozzle defines a lumen that has a first cross-sectional shape at a proximal end of the nozzle and that has a second cross-sectional shape at a distal end of the nozzle, the second cross-sectional shape different from the first cross-sectional shape, the second cross-sectional shape being rectangular, the second cross-sectional shape having an area smaller than an area of the first cross-sectional shape.
 10. The system of claim 1, wherein a portion of a length of the nozzle between a proximal end of the nozzle and a distal end of the nozzle defines a curve in a direction of the portion of the length that is configured to promote a substantially even pressure distribution of the flow of air as the flow of air is output from the nozzle.
 11. The system of claim 1, wherein the nozzle includes a nozzle exhaust at a distal end of the nozzle, the nozzle defines a curve along a portion of a length of the nozzle between a proximal end of the nozzle and the distal end of the nozzle, the nozzle exhaust positioned at a lower portion of the roasting chamber such that the flow of air output from the nozzle exhaust and into the roasting chamber can loft a portion of a substance within the roasting chamber.
 12. A system, comprising: a roasting chamber coupled to an air flow path; a cyclonic separator coupled to the air flow path such that the cyclonic separator receives air output from the roasting chamber, the cyclonic separator configured to separate a portion of a substance from the air; a catalytic oxidizer coupled to the air flow path and configured to receive the air after the cyclonic separator; a blower coupled to the air flow path, the blower configured to pressurize ambient air; and a nozzle coupled to the air flow path, the nozzle having an internal configuration that accelerates at least a portion of the air output to the roasting chamber, the air flow path arranged to mix ambient air pressurized by the blower and heated air previously circulated through the air flow path.
 13. The system of claim 12, further comprising: a heater coupled to the air flow path and configured to increase a temperature of the air to the air flow path.
 14. The system of claim 12, further comprising: a heat exchanger coupled to the air flow path between the catalytic oxidizer and the nozzle.
 15. The system of claim 12, wherein the internal configuration of the nozzle includes (1) a decrease in cross-sectional area from a proximal end of the nozzle to a distal end of the nozzle, and (2) a curve in the nozzle of between 90° and 135° between the proximal end of the nozzle and the distal end of the nozzle.
 16. The system of claim 12, wherein the nozzle defines a lumen that has a rectangular cross-sectional shape at a distal end of the nozzle through which the air is output to a lower portion of the roasting chamber.
 17. A system, comprising: a roasting chamber coupled to a recirculating air path, the roasting chamber configured to mechanically circulate a substance within the roasting chamber; a blower coupled to the recirculating air path, the blower configured to provide air to the recirculating air path; a nozzle coupled to the recirculating air path, the nozzle including a non-linear portion between a proximal end portion of the nozzle and a distal end portion of the nozzle, the distal end portion of the nozzle having a reduced cross-sectional area compared to the proximal end portion of the nozzle, the non-linear portion of the nozzle configured to modulate output of the air into the roasting chamber such that the air is configured to loft at least a portion of the substance within the roasting chamber; and a serial arrangement of a cyclonic separator, a heater and a catalytic oxidizer, each coupled to the recirculating air path such that the air received respectively therein was previously output from the roasting chamber.
 18. The system of claim 17, wherein the recirculating air path is arranged such that the air output from the catalytic oxidizer is configured to be mixed with the air provided by the blower before being output to the roasting chamber via the nozzle.
 19. The system of claim 17, wherein the nozzle includes a curve of between 90° and 135° between the proximal end portion of the nozzle and the distal end portion of the nozzle.
 20. The system of claim 17, wherein the cross-sectional area of the distal end portion of the nozzle is rectangular. 